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99500-94L10-01E

99500-94L10-01E
2014

DIC567 Pantone 303C Pantone 485 Pantone 294 Black

99500-94L10-01E DF25A/30A Service Manual Cover for PS printing (14mm) 5/0 2014/05/24 BOTTOM
 IMPORTANT NOTICE

WARNING / CAUTION / NOTICE / NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and
the words ! WARNING , ! CAUTION , NOTICE and NOTE have special meanings.
Pay special attention to the messages highlighted by these signal words.

! WARNING
Indicates a potential hazard that could result in death or serious injury.

! CAUTION
Indicates a potential hazard that could result in minor or moderate injury.

NOTICE
Indicates a potential hazard that could result in damage to the motor or boat.

NOTE
Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all poten-
tial hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the ! WARNING ,
! CAUTION , and NOTICE stated, you must also use good judgment and observe basic mechanical safety prin-

ciples.

! WARNING
This service manual is intended for authorized Suzuki outboard motor dealers and qualified service
technicians only.
Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment
may not be able to properly perform the services described in this manual. Improper repair may result
in injury to the mechanic and may render the engine unsafe for the boat operator and passengers.
 FOREWORD
This manual contains an introductory description of the SUZUKI DF25A/30A Outboard motors and procedures for
inspection, service and overhaul of their main components.
General knowledge information is not included.
Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning this
motor. Read and refer to the other sections in this manual for information regarding proper inspection and service
procedures.
This manual will help you better understand these outboard motors, assisting you in providing your customers
with optimum and quick service.

* This manual has been prepared using the latest information available at the time of publication. Differences
may exist between the content of this manual and the actual outboard motor.
* Illustrations in this manual are used to show the basic principles of operation and work procedures and may
not represent the actual outboard motor in exact detail.
* This manual is intended for use by technicians who already possess the basic knowledge and skills to ser-
vice SUZUKI Outboard motors. Persons without such knowledge and skills should not attempt to service
Suzuki Outboard engines by relying on this manual only and should contact an authorized SUZUKI Out-
board motor dealer.

NOTE:
This manual is compiled with the production model manufactured in May, 2014.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2014

 00
TABLE OF CONTENTS

Precautions............................................................... 00-i
Precautions ............................................................ 00-1 1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Tune-Up..................................... 0B-1
Power Head................................................................. 1-i
2
Precautions .............................................................. 1-1
Engine Control ....................................................... 1A-1
Engine Electrical Devices.......................................1C-1
Power Unit Mechanical ..........................................1D-1 3
Power Unit Lubrication ........................................... 1E-1
Power Unit Cooling System ................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System.......................................................1H-1
Starting System....................................................... 1I-1 4
Manual Starting System ..........................................1J-1
Charging System.................................................... 1K-1
Mid Unit ....................................................................... 2-i
Precautions .............................................................. 2-1 5
Housing and Bracket.............................................. 2A-1
Power Trim and Tilt ................................................ 2B-1
Lower Unit................................................................... 3-i
Precautions .............................................................. 3-1 6
Right Hand Rotation Unit ....................................... 3A-1
Wire / Hose Routing ................................................... 4-i
Precautions .............................................................. 4-1
Wire Routing .......................................................... 4A-1 7
Fuel / Water Hose Routing..................................... 4B-1

10

11

12
 Table of Contents 00- i

Section 00
00

Precautions
CONTENTS

Precautions ...............................................00-1 Precautions........................................................... 00-1

General Precautions ........................................... 00-1
00-1 Precautions:

Precautions
Precautions

Precautions
General Precautions
CENFL3120000001
The WARNING, CAUTION and NOTICE messages below describe some general precautions that you should observe
when servicing the outboard motor. These general precautions apply to many of the service procedures, but they will
not necessarily be repeated for every procedure to which they apply.

! WARNING
Failure to take proper precautions when servicing the outboard motor can cause severe personal
injury.
• To avoid eye injury, always wear protective glasses when filing metals, working on a grinder, or
doing other work, which could cause debris.
• When two or more persons work together, pay attention to the safety of each other.
• When it is necessary to run the outboard motor indoors, make sure that exhaust gas is vented
outdoors.
• When testing an outboard motor in the water, ensure that the necessary safety equipment is on
board.
Such equipment includes: flotation aids for each person, fire extinguisher, distress signals, anchor,
paddles, bilge pump, first aid kit, emergency starter rope, etc.
• Whenever handling toxic or flammable materials, wear safety glasses to protect your eyes. Any
toxic or flammable materials getting into your eye may cause inflammation. Also wear moisture-
proof gloves to protect your skin.
• Do not swallow any toxic or flammable materials. Swallowing them could cause diarrhea, nausea or
other health problems. Be especially careful not to allow children and pets to swallow these
materials.
• Keep all toxic or flammable materials out of reach of children and pets.
• When working with toxic or flammable materials, make sure that the area you work in is well
ventilated and that you follow all of the material manufacturer’s instructions.
• Never use gasoline as a cleaning solvent.
• To avoid getting burned, do not touch the engine, engine oil or exhaust system during or shortly
after engine operation.
• Avoid contact with new and used oil. Prolonged contact with used oil has been shown to cause skin
cancer in laboratory animals. Brief contact with used oil may irritate the skin. Keep new and used oil
away from children and pets. To minimize your exposure to oil, wear a long sleeve shirt and
moisture - proof gloves (such as latex gloves) when changing oil. If oil contacts your skin, wash
thoroughly with soap and water. Launder any clothing or rags if wet with oil. Recycle or properly
dispose of used oil.
• Never disconnect any of the fuel lines between the fuel pump and injectors without first releasing
the fuel pressure, or fuel can be sprayed out under pressure.
• After servicing the fuel, lubrication, cooling and/or the exhaust system, check all lines and fittings
related to the system for leaks.
• Carefully adhere to the battery handling instructions laid out by the battery supplier.
 Precautions: 00-2

NOTICE
Failure to take proper precautions when servicing the outboard motor can cause damage to the parts
or the outboard motor.
To prevent the parts or the outboard motor from damage, be sure to take the following precautions:
• When removing parts that are to be reused, keep them arranged in an orderly manner so that they
may be reinstalled in the proper order and orientation.
• Be sure to use special tools where instructed.
• Make sure that all parts used in assembly are clean and also lubricated when specified.
• When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified
type.
• When removing the battery, disconnect the negative cable first and then the positive cable. When
reconnecting the battery, connect the positive cable first and then the negative cable.
• When performing service to electrical parts, if the service procedures do not require using battery
power, disconnect the negative cable at the battery.
• Do not expose connectors and electrical parts to water, which will cause electrical systems
problems.
• Always be careful not to drop electrical components (ECM, relays, etc.) or handle them in a rough
manner.
• Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, locking nuts, cotter
pins, circlips, and certain other parts as specified, always replace them with new ones. Also, before
installing these new parts, be sure to remove any left over material from the mating surfaces.
• Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than
required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely
seated in its groove and securely fitted.
• Use a torque wrench to tighten fasteners to the torque values when specified.
• Remove grease or oil from screw / bolt threads unless a lubricant is specified.
• After assembly, check parts for tightness and proper operation.

NOTE
• To protect the environment, do not unlawfully dispose of used motor oil, other fluids or batteries.
• To protect the Earth's natural resources, properly dispose of used motor parts.

Replacement Parts

NOTICE
Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to
performance problems and damage.
Use only genuine SUZUKI replacement parts or their equivalent. Genuine SUZUKI parts are high
quality parts which are designed and built specially for SUZUKI outboard motors.

If parts replacement is necessary, Suzuki strongly recommends that you use genuine Suzuki parts or their equivalent.
They are precision-made to ensure high quality and correct fit.
00-3 Precautions:
 Table of Contents 0- i

Section 0

General Information
0
CONTENTS

General Information ................................ 0A-1 Lubrication Point .................................................0B-2

General Description .............................................0A-1 Service Instructions .............................................0B-3
Symbols .............................................................. 0A-1 Engine Oil Level Check.......................................0B-3
Abbreviations ...................................................... 0A-1 Engine Oil Change and Engine Oil Filter
Wire Color Symbols ............................................ 0A-2 Replacement .....................................................0B-3
Warning, Caution and Information Label Gear Oil Change .................................................0B-6
Locations........................................................... 0A-3 Spark Plug Removal and Installation ..................0B-6
Outboard Motor Identification Number Spark Plug Inspection and Cleaning ...................0B-7
Location ............................................................ 0A-4 Valve Clearance Inspection and Adjustment ......0B-8
Fuel and Oil Recommendations.......................... 0A-4 Timing Belt Inspection.........................................0B-9
Break-In Procedures ........................................... 0A-5 Timing Belt Replacement ..................................0B-10
Propeller Selection Guide ................................... 0A-6 Idle Speed and Idle Air Control (IAC) Duty
Battery Requirement ........................................... 0A-6 Inspection........................................................0B-13
Specifications.......................................................0A-7 Ignition Timing Inspection .................................0B-15
Specifications (DF25A) ....................................... 0A-7 Breather Line and Fuel Line Inspection ............0B-16
Specifications (DF30A) ....................................... 0A-9 Low Pressure Fuel Filter Inspection..................0B-17
Service Data ..................................................... 0A-11 In-line Fuel Filter Replacement .........................0B-17
Tightening Torque Specifications...................... 0A-16 Water Pump and Water Pump Impeller
Inspection........................................................0B-18
Special Tools and Equipment ...........................0A-17
Propeller / Propeller Nut and Cotter Pin
Recommended Service Material ....................... 0A-17
Inspection........................................................0B-18
Special Tool ...................................................... 0A-18
Anodes Inspection.............................................0B-19
Maintenance and Tune-Up...................... 0B-1 Bonding Wire Inspection ...................................0B-19
Battery Inspection .............................................0B-20
Precautions...........................................................0B-1
Thermostat Inspection.......................................0B-21
Precautions for Maintenance .............................. 0B-1
Air Cleaner Element Inspection.........................0B-21
General Description .............................................0B-1
Bolts and Nuts Inspection .................................0B-21
Recommended Oil and Lubricants...................... 0B-1
Oil Pressure Check ...........................................0B-22
Scheduled Maintenance ......................................0B-1 Cylinder Compression Pressure Check ............0B-23
Periodic Maintenance Schedule Chart................ 0B-1
0A-1 General Information:

General Information
General Information

General Description
Symbols
CENFL3120101001
Listed in the table below are the symbols indicating instructions and other important information necessary for proper
servicing.
Please note the definition for each symbol. You will find these symbols used throughout this manual.
Refer back to this table if you are not sure of any symbol(s) meanings.
Symbol Definition
Torque control required.
Data beside it indicates specified torque.
Apply oil.
Use engine oil unless otherwise specified.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1)
Apply SUZUKI Outboard Motor Gear Oil.
Apply SUZUKI Super Grease A.
Apply SUZUKI Moly Paste.
99000-25140
Apply SUZUKI Water Resistant Grease.
Apply SUZUKI Bond 1207B.
Apply SUZUKI Silicone Seal.
Apply SUZUKI Thread Lock 1342.
Apply SUZUKI Thread Lock Super 1333B.
Use special tool.
Do not reuse.
Note on reassembly.
Use peak voltmeter Stevens CD-77.

Abbreviations I:
CENFL3120101002 IAC: Idle Air Control
Abbreviations used in this service manual are as follows:
IAT: Intake Air Temperature
A:
IG: Ignition
ATDC: After Top Dead Center
Ign.: Ignition
AC: Alternating Current
IN (In.): Intake
B:
L:
BTDC: Before Top Dead Center
LPS: Lever Position Sensor
C:
M:
CKP Sensor: Crankshaft Position sensor
MAP: Manifold Absolute Pressure
CMP Sensor: Camshaft Position sensor
P:
CTP: Close Throttle Position
PCV: Positive Crankcase Ventilation
D:
PORT: Port
DC: Direct Current
PTT: Power Trim and Tilt
E:
S:
ECM: Engine Control Module
SPS: Shift Position Sensor
EX (Ex.): Exhaust
STBD: Starboard
F:
SIGP: Start-In-Gear Protection
FP: Fuel Pump
T:
G:
TPS: Throttle Position Sensor
GND: Ground
 General Information: 0A-2

Wire Color Symbols

CENFL3120101003
There are two kinds of colored wire used in this product.
One is single colored wire and the other is dual colored (striped) wire.
The single colored wire uses only one color symbol. example: B (Black).
The dual colored wire uses two color symbols. example: Bl/B.
The first symbol represents the base color of the wire and the second symbol represents the color of the stripe.
Example: Bl/B (Blue with Black stripe).
Symbol Wire color Symbol Wire color
B Black Lg Light green
Bl Blue O Orange
Br Brown P Pink
Dg Dark green R Red
G Green V Violet
Gr Gray W White
Lbl Light blue Y Yellow

B (Base Color: Black)

Bl (Base Color: Blue) Bl/B

B (Stripe Color: Black)

IFL311010001-02
0A-3 General Information:

Warning, Caution and Information Label Locations

CENFL3120101004
The figure shows main labels among others that are attached to outboard motor.
When servicing outboard motor, refer to WARNING/CAUTION instructions printed on labels.
If any WARNING/CAUTION label is found stained or damage, clean or replace it as necessary.
Do not reuse a label after it has been removed. Always use new label.

8 WARNING
AVERTISSEMENT
• Fuel can leak creating a fire hazard if
you lay motor on its side. Drain fuel
completely from vapor separator or
carburetor before laying motor on its side.
• See owner’s manual for details.
• Le carburant risque de fuir et de
présenter un danger d’incendie si le
moteur est placé sur le côté.
Vidanger entičrement le carburant du
séparateur de vapeurs ou du
carburateur avant de procéder.
• Pour plus de détail, voir le manuel
du propriétaire.
2

IFL311010004-04

IFL311010005-05

1. Label, engine cover 3. Label, recoil starter 5. Fuel tank

2. Label, clamp bracket 4. Label S.I.G.P.
 General Information: 0A-4

Outboard Motor Identification Number Location Fuel and Oil Recommendations

CENFL3120101005 CENFL3120101006
Model, Pre-Fix, Serial Number Gasoline
The Model, Pre-fix and Serial number of motor are
stamped on a plate attached to the clamp bracket. NOTICE
Use of leaded gasoline can cause engine
damage.
Use of improper or poor quality fuel can
affect performance and may damage the
motor and fuel system.

Use only unleaded gasoline. Do not use fuel

1
having lower than the recommended octane,
or fuel that may be stale or contaminated by
dirt/water etc.

Suzuki highly recommends that you use alcohol-free

IFL311010006-02
unleaded gasoline with a minimum pump octane rating
1. Identification number plate of 87 (R/2+M/2 method) or 91 (Research method).
However, blends of unleaded gasoline and alcohol with
Example equivalent octane content may be used.
1 Allowable maximum blend of a single additive (Not
combination)
5% Methanol, 10% Ethanol, 15% MTBE
DF 30A
Engine Oil
03003F
NOTICE
THAI SUZUKI MOTOR CO.,LTD.
MADE IN THAILAND FABRIQUE AU THAILANDE Use of a poor quality engine oil can adversely
affect engine performance and life.
2 3
IFL311010002-02
Suzuki recommends that you use Suzuki
1. Model 2. Pre-fix 3. Serial number Marine 4-Cycle Engine Oil or its equivalent.

Engine Serial Number Location Oil quality is a major contributor to your engine’s
A second engine serial number plate is pressed into a performance and life. Always select good quality engine
boss on the cylinder block. oil.
Suzuki recommends the use of SAE 10W-40 or 10W-30
SUZUKI MARINE 4-CYCLE ENGINE OIL.
If SUZUKI MARINE 4-CYCLE ENGINE OIL is not
available, select a NMMA certified FC-W oil or good
1
quality 4-cycle motor oil from the following chart
XXXXXX according to the average temperatures in your area.

API Classification SAE Viscosity Grade

SG
SH 10W–40
SJ
SL
IFL311010007-03 10W–30
SM
1. Serial number plate
C –20 –10 0 10 20 30 40
TEMP.
F –4 14 32 50 68 86 104
I9J011010003-02

Gear Oil
Suzuki recommends the use of SUZUKI Outboard Motor
Gear Oil. If it is not available, use SAE 90 hypoid gear oil
which is rated GL-5 under the API classification system.
0A-5 General Information:

Break-In Procedures Throttle Recommendation

CENFL3120101007
NOTICE NOTE
Failure to follow the break-in procedures Avoid maintaining a constant engine speed
described below can result in severe engine for an extended period at any time during the
damage. engine break-in period by varying the throttle
position occasionally.
Be sure to follow the engine break-in
procedures described below. First 2 hours
For the first 15 minutes, operate the engine in-gear at
The first 10 hours are critically important to ensure idling speed. During the remaining 1 hour and 45
correct running of either a brand new motor or a motor minutes, operate the engine in-gear at less than 1/2
that has been reconditioned or rebuilt. How the motor is (half) throttle (3 000 r/min).
operated during this time will have direct bearing on its
life span and long-term durability. NOTE

Break-in period The throttle may be briefly opened beyond

10 hours the recommended setting to plane the boat,
but must be reduced to the recommended
Warm-Up Recommendation setting immediately after planning.
NOTICE
Next 1 hour
Running at high speed without sufficient
Operate the engine in-gear at less than 3/4 (three -
warm-up may cause severe engine damage
quarter) throttle (4 000 r/min).
such as piston seizure.
Last 7 hours
Always allow sufficient idling time (5
Operate the engine in-gear at a desired engine speed.
minutes) for the engine to warm-up before
However, do not operate continuously at full throttle for
running at high speed.
more than 5 minutes.
Allow sufficient idling time (more than 5 minutes) for the NOTICE
engine to warm up after cold engine starting.
Running continuously at full throttle for more
than 5 minutes at a time during the last 7
hours of break-in operation may cause
severe engine damage such as seizure.

During the last 7 hours of break-in operation,

do not operate at wide open throttle for more
than 5 minutes at a time.
 General Information: 0A-6

Propeller Selection Guide Battery Requirement

CENFL3120101008 CENFL3120101009
An outboard motor is designed to develop its rated Suzuki recommends a 12 V cranking type lead acid
power within a specified engine speed range. The battery for the DF25A/30A.
maximum rated power delivered by the DF25A/30A Minimum battery requirement for starting the engine is
models are shown below. provided below.
The battery must satisfy one of the specifications
Recommended full throttle speed range described below.
DF25A 5 000 – 6 000 r/min
DF30A 5 300 – 6 300 r/min NOTE
• The specifications listed below are the
NOTICE minimum battery rating requirements for
Installing a propeller with either too much or starting the engine.
too little pitch will cause incorrect maximum • Additional electrical loads from the boat
engine speed, which may result in severe will require larger capacity batteries.
damage to the motor. • Dual-purpose (Cranking/Deep Cycle)
batteries can be used if they meet the
Select a propeller that will allow the engine to minimum specifications listed below
reach the recommended operating range at (MCA, CCA, or RC).
full throttle with the maximum boat load.
• Do not use a Deep Cycle battery for the
If the standard propeller fails to meet the above main cranking battery.
requirement, use another pitch propeller to hold the • The use of Maintenance-Free, sealed, or
engine speed within the range specified above. Gel-Cell batteries is not recommended
because they may not be compatible with
Propeller size chart Suzuki’s charging system.
Blade x Dia. (in.) x Pitch (in.) • When connecting batteries in parallel, they
3 x 10 and 1/4 x 9 must be of the same type, capacity,
3 x 10 and 1/4 x 10 manufacturer, and of similar age. When
3 x 10 and 1/4 x 11 replacement is necessary, they should be
3 x 10 and 1/4 x 12 replaced as a set.
3 x 10 and 1/4 x 13
• It is recommended that the battery be
3 x 10 and 1/4 x 14
installed in an enclosed case.
3 x 10 and 1/4 x 15
• When connecting batteries, hexagon nuts
must be used to secure battery leads to
battery terminals.

Battery specification
650 Marine Cranking Amps (MCA)/ABYC, or 512 Cold
Cranking Amps (CCA)/SAE or 160 Reserve Capacity
(RC) Minutes/SAE or 12 V 70 AH
0A-7 General Information:

Specifications
Specifications (DF25A)
CENFL3120107001
NOTE
• These specifications are subject to change without notice.
• For DF30A specification, refer to “Specifications (DF30A)” (Page 0A-9).

Model Pre-fix
Data
Item Unit
DF25A DF25AE DF25AR DF25AQ DF25AQE DF25ATH DF25AT
PRE-FIX 02504F

Dimensions and Weight

Data
Item Unit
DF25A DF25AE DF25AR DF25AQ DF25AQE DF25ATH DF25AT
Overall length (front to
mm (in.) 696 (27.4) 645 (25.4) 696 (27.4) 673 (26.5)
back)
Overall width (side to
mm (in.) 394 (15.5)
side)
S mm (in.) 1 230 (48.4)
Overall height
L mm (in.) 1 357 (53.4)
X mm (in.) —
S kg (lbs) 63 (139) 66 (145) 64 (141) 69 (152) 73 (161) 74 (163) 72 (159)
Weight (without
L kg (lbs) 64 (141) 67 (148) 66 (145) 71 (156) 74 (163) 75 (165) 73 (161)
engine oil)
X kg (lbs) — — — — — — —
S mm (in. type) 422 (15)
Transom height L mm (in. type) 549 (20)
X mm (in. type) —

Performance
Data
Item Unit
DF25A DF25AE DF25AR DF25AQ DF25AQE DF25ATH DF25AT
Maximum output kW (PS) 18.4 (25)
Recommended
r/min 5 000 – 6 000
operating range
Idle speed r/min 850 ± 50 (in-gear: Approx. 800 – 900)

Powerhead
Data
Item Unit
DF25A DF25AE DF25AR DF25AQ DF25AQE DF25ATH DF25AT
Engine type 4-stroke SOHC
Number of cylinders 3
Bore mm (in.) 60.4 (2.38)
Stroke mm (in.) 57.0 (2.24)
Total displacement cm3 (cu. in) 490 (29.90)
Compression ratio :1 10.1
Spark plug NGK CPR6EA-9
Ignition system Digital CDI
Fuel supply system Electronic fuel injection
Exhaust system Through prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Manual Electric Manual Electric
Choke system —
Remote Remote
Throttle control Twist grip Twist grip
control control
 General Information: 0A-8

Fuel and Oil

Data
Item Unit
DF25A DF25AE DF25AR DF25AQ DF25AQE DF25ATH DF25AT
Suzuki highly recommends the use of alcohol-free unleaded gasoline with a
minimum pump octane rating of 87 (R/2+M/2 method) or 91 (Research
Fuel
method). However, blends of unleaded gasoline and alcohol with equivalent
octane content may be used.
• API classification: SG, SH, SJ, SL, SM or NMMA certified FC-W oil
Engine oil
• Viscosity rating: SAE 10W-40 or 10W-30, NMMA FC-W 10W-40 or 10W-30
1.5 (1.6/1.3): Oil change only
Engine oil amounts L (US/lmp. qt)
1.7 (1.8/1.5): Oil filter change
SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear oil, API classification
Gear oil
GL-5.
Gearcase oil
ml (US/lmp. oz) 330 (11.1 / 11.6)
capacity

Bracket
Data
Item Unit
DF25A DF25AE DF25AR DF25AQ DF25AQE DF25ATH DF25AT
Manual and gas-
Trim/Tilt system Manual PTT
assisted
Trim angle degree 0 – 16 (–8 to 8) 0 – 16 (–4 to 12)
Number of tilt pin
5
position
Maximum tilt angle degree 69.5 (–8 to 61.5) 66.2 (–4 to 62.2) 66.8 (–4 to 62.8)

Lower Unit
Data
Item Unit
DF25A DF25AE DF25AR DF25AQ DF25AQE DF25ATH DF25AT
Reversing system Gear
Transmission Forward-Neutral-Reverse
Reduction system Bevel gear
Gear ratio 11 : 23 (2.09)
Drive line impact protection Spline drive rubber hub
Propeller shaft rotation (when shift
Clockwise
into forward)
Blade x Dia. (in.) x Pitch (in.)
3 x 10 and 1/4 x 9
3 x 10 and 1/4 x 10
3 x 10 and 1/4 x 11
Propeller
3 x 10 and 1/4 x 12
3 x 10 and 1/4 x 13
3 x 10 and 1/4 x 14
3 x 10 and 1/4 x 15
0A-9 General Information:

Specifications (DF30A)
CENFL3120107004
NOTE
• These specifications are subject to change without notice.
• For DF25A specification, refer to “Specifications (DF25A)” (Page 0A-7).

Model Pre-fix
Data
Item Unit
DF30A DF30AE DF30AR DF30AQ DF30AQE DF30ATH DF30AT
PRE-FIX 03003F

Dimensions and Weight

Data
Item Unit
DF30A DF30AE DF30AR DF30AQ DF30AQE DF30ATH DF30AT
Overall length (front to
mm (in.) 696 (27.4) 645 (25.4) 696 (27.4) 673 (26.5)
back)
Overall width (side to
mm (in.) 394 (15.5)
side)
S mm (in.) 1 230 (48.4)
Overall height
L mm (in.) 1 357 (53.4)
X mm (in.) —
S kg (lbs) 63 (139) 66 (145) 64 (141) 69 (152) 73 (161) 74 (163) 72 (159)
Weight (without
L kg (lbs) 64 (141) 67 (148) 66 (145) 71 (156) 74 (163) 75 (165) 73 (161)
engine oil)
X kg (lbs) — — — — — — —
S mm (in. type) 422 (15)
Transom height L mm (in. type) 549 (20)
X mm (in. type) —

Performance
Data
Item Unit
DF30A DF30AE DF30AR DF30AQ DF30AQE DF30ATH DF30AT
Maximum output kW (PS) 22.1 (30)
Recommended
r/min 5 300 – 6 300
operating range
Idle speed r/min 850 ± 50 (in-gear: Approx. 800 – 900)

Powerhead
Data
Item Unit
DF30A DF30AE DF30AR DF30AQ DF30AQE DF30ATH DF30AT
Engine type 4-stroke SOHC
Number of cylinders 3
Bore mm (in.) 60.4 (2.38)
Stroke mm (in.) 57.0 (2.24)
Total displacement cm3 (cu. in) 490 (29.90)
Compression ratio :1 10.1
Spark plug NGK CPR6EA-9
Ignition system Digital CDI
Fuel supply system Electronic fuel injection
Exhaust system Through prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Manual Electric Manual Electric
Choke system —
Remote Remote
Throttle control Twist grip Twist grip
control control
 General Information: 0A-10

Fuel and Oil

Data
Item Unit
DF30A DF30AE DF30AR DF30AQ DF30AQE DF30ATH DF30AT
Suzuki highly recommends the use of alcohol-free unleaded gasoline with a
minimum pump octane rating of 87 (R/2+M/2 method) or 91 (Research
Fuel
method). However, blends of unleaded gasoline and alcohol with equivalent
octane content may be used.
• API classification: SG, SH, SJ, SL, SM or NMMA certified FC-W oil
Engine oil
• Viscosity rating: SAE 10W-40 or 10W-30, NMMA FC-W 10W-40 or 10W-30
1.5 (1.6/1.3): Oil change only
Engine oil amounts L (US/lmp. qt)
1.7 (1.8/1.5): Oil filter change
SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear oil, API classification
Gear oil
GL-5.
Gearcase oil
ml (US/lmp. oz) 330 (11.1 / 11.6)
capacity

Bracket
Data
Item Unit
DF30A DF30AE DF30AR DF30AQ DF30AQE DF30ATH DF30AT
Manual and gas-
Trim/Tilt system Manual PTT
assisted
Trim angle degree 0 – 16 (–8 to 8) 0 – 16 (–4 to 12)
Number of tilt pin
5
position
Maximum tilt angle degree 69.5 (–8 to 61.5) 66.2 (–4 to 62.2) 66.8 (–4 to 62.8)

Lower Unit
Data
Item Unit
DF30A DF30AE DF30AR DF30AQ DF30AQE DF30ATH DF30AT
Reversing system Gear
Transmission Forward-Neutral-Reverse
Reduction system Bevel gear
Gear ratio 11 : 23 (2.09)
Drive line impact protection Spline drive rubber hub
Propeller shaft rotation (when shift
Clockwise
into forward)
Blade x Dia. (in.) x Pitch (in.)
3 x 10 and 1/4 x 9
3 x 10 and 1/4 x 10
3 x 10 and 1/4 x 11
Propeller
3 x 10 and 1/4 x 12
3 x 10 and 1/4 x 13
3 x 10 and 1/4 x 14
3 x 10 and 1/4 x 15
0A-11 General Information:

Service Data
CENFL3120107002
NOTE
*These service data are subject to change without notice.
*The following data is applied to all version of each model of DF25A/30A.

Powerhead
Data
Item Unit
DF25A DF30A
Recommended operating range r/min 5 000 – 6 000 5 300 – 6 300
Idle speed r/min 850 ± 50 (in-gear: Approx. 800 – 900)
kPa 500 – 1 000 (5 – 10, 71 – 142) (Crank with recoil starter)
**Cylinder compression pressure
(kgf/cm2, psi.) 500 – 1 800 (5 – 18, 71 – 256) (Crank with electric starter)
**Cylinder compression pressure kPa
100 (1.0, 14)
max. difference between cylinders (kgf/cm2, psi.)
kPa 200 – 500 (2.0 – 5.0, 28 – 71) at 3 000 r/min. (at normal
**Engine oil pressure
(kgf/cm2, psi.) operating temp.)
• API classification: SG, SH, SJ, SL, SM or NMMA certified FC-
W oil
Engine oil
• Viscosity rating: SAE 10W-40 or 10W-30, NMMA FC-W 10W-
40 or 10W-30
1.5 (1.6/1.3): Oil change only
Engine oil amounts L (US/lmp. qt)
1.7 (1.8/1.5): Oil filter change
Thermostat operating temperature °C (°F) 58 – 62 (136 – 144)

**Figures shown are guidelines only, not absolute service limits

Cylinder Head / Camshaft

Data
Item Unit
DF25A DF30A
Cylinder head distortion Limit mm (in.) 0.06 (0.002)
Manifold seating faces distortion Limit mm (in.) 0.06 (0.002)
std. mm (in.) 25.430 – 25.490 (1.0012 – 1.0035)
IN
Limit mm (in.) 25.330 (0.9972)
Cam height
std. mm (in.) 25.140 – 25.200 (0.9898 – 0.9921)
EX
Limit mm (in.) 25.040 (0.9858)
Top, std. mm (in.) 0.020 – 0.062 (0.0008 – 0.0024)
Camshaft journal oil Lower Limit mm (in.) 0.100 (0.0039)
clearance std. mm (in.) 0.025 – 0.075 (0.0010 – 0.0030)
Center
Limit mm (in.) 0.100 (0.0039)
std. mm (in.) 27.000 – 27.021 (1.0630 – 1.0638)
Top
Limit mm (in.) —
Camshaft journal inside std. mm (in.) 34.500 – 34.525 (1.3583 – 1.3593)
Center
diameter (from MAG side) Limit mm (in.) —
std. mm (in.) 23.000 – 23.021 (0.9055 – 0.9063)
Lower
Limit mm (in.) —
std. mm (in.) 26.959 – 26.980 (1.0614 – 1.0622)
Top
Limit mm (in.) —
Camshaft journal outside std. mm (in.) 34.450 – 34.475 (1.3563 – 1.3573)
Center
diameter (from MAG side) Limit mm (in.) —
std. mm (in.) 22.959 – 22.980 (0.9039 – 0.9047)
Lower
Limit mm (in.) —
Camshaft runout Limit mm (in.) 0.10 (0.004)
Rocker arm shaft to rocker std. mm (in.) 0.013 – 0.039 (0.0005 – 0.0015)
IN, EX
arm clearance Limit mm (in.) 0.060 (0.0024)
Rocker arm shaft outside
IN, EX std. mm (in.) 11.979 – 11.990 (0.4716 – 0.4720)
diameter
Rocker arm inside diameter IN, EX std. mm (in.) 12.003 – 12.018 (0.4726 – 0.4731)
Rocker arm shaft runout IN, EX Limit mm (in.) 0.120 (0.005)
 General Information: 0A-12

Valve / Valve Guide

Data
Item Unit
DF25A DF30A
IN mm (in.) 29.0 (1.14)
Valve diameter
EX mm (in.) 26.0 (1.02)
Valve clearance IN std. mm (in.) 0.18 – 0.22 (0.007 – 0.009)
(Cold engine condition) EX std. mm (in.) 0.20 – 0.24 (0.008 – 0.009)
IN degree 15°, 45°
Valve seat angle
EX degree 15°, 45°
std. mm (in.) 0.010 – 0.037 (0.0004 – 0.0015)
IN
Valve guide to valve stem Limit mm (in.) 0.070 (0.0028)
clearance std. mm (in.) 0.030 – 0.057 (0.0012 – 0.0022)
EX
Limit mm (in.) 0.090 (0.0035)
IN,
Valve guide inside diameter std. mm (in.) 5.000 – 5.012 (0.1969 – 0.1973)
EX
IN,
Valve guide protrusion std. mm (in.) 10.6 – 11.0 (0.42 – 0.43)
EX
IN std. mm (in.) 4.975 – 4.990 (0.1959 – 0.1965)
Valve stem outside diameter
EX std. mm (in.) 4.955 – 4.970 (0.1950 – 0.1957)
IN Limit mm (in.) 0.14 (0.006)
Valve stem deflection
EX Limit mm (in.) 0.18 (0.007)
IN Limit mm (in.) 0.05 (0.002)
Valve stem runout
EX Limit mm (in.) 0.05 (0.002)
IN,
Valve head radial runout Limit mm (in.) 0.08 (0.003)
EX
std. mm (in.) —
IN
Limit mm (in.) 0.5 (0.02)
Valve head thickness
std. mm (in.) —
EX
Limit mm (in.) 0.5 (0.02)
IN std. mm (in.) 0.9 – 1.1 (0.035 – 0.043)
Valve seat contact width
EX std. mm (in.) 0.9 – 1.1 (0.035 – 0.043)
std. mm (in.) 34.29 (1.350)
Valve spring free length
Limit mm (in.) 32.92 (1.296)
std. N (kg, lbs) 85 – 94 (8.5 – 9.4, 18.8 – 20.8) at 28.5 mm (1.12 in.)
Valve spring preload
Limit N (kg, lbs) 75 (7.5, 16.5) at 28.5 mm (1.12 in.)
Valve spring squareness Limit mm (in.) 1.5 (0.06)

Cylinder / Piston / Piston Ring

Data
Item Unit
DF25A DF30A
Cylinder distortion Limit mm (in.) 0.06 (0.002)
std. mm (in.) 0.0271 – 0.0425 (0.0011 – 0.0017)
Piston to cylinder clearance
Limit mm (in.) 0.100 (0.0039)
Cylinder bore std. mm (in.) 60.400 – 60.415 (2.3780 – 2.3785)
Cylinder measuring position mm (in.) 50 (1.969) from cylinder top surface
Piston skirt diameter std. mm (in.) 60.365 – 60.380 (2.3766 – 2.3772)
Piston measuring position mm (in.) 9 (0.354) from piston skirt end
Cylinder bore wear Limit mm (in.) 0.100 (0.0039)
std. mm (in.) 0.12 – 0.25 (0.0047 – 0.0098)
1st
Limit mm (in.) 0.70 (0.028)
Piston ring end gap
std. mm (in.) 0.26 – 0.39 (0.0102 – 0.0154)
2nd
Limit mm (in.) 0.70 (0.028)
std. mm (in.) Approx. 6.3 (0.2480)
1st
Limit mm (in.) 5.0 (0.1969)
Piston ring free end gap
std. mm (in.) Approx. 5.6 (0.2205)
2nd
Limit mm (in.) 4.5 (0.1772)
0A-13 General Information:

Data
Item Unit
DF25A DF30A
std. mm (in.) 0.030 – 0.070 (0.0012 – 0.0028)
1st
Piston ring to groove Limit mm (in.) 0.12 (0.005)
clearance std. mm (in.) 0.020 – 0.060 (0.0008 – 0.0024)
2nd
Limit mm (in.) 0.10 (0.004)
1st std. mm (in.) 1.02 – 1.04 (0.040 – 0.041)
Piston ring groove width 2nd std. mm (in.) 1.21 – 1.23 (0.048 – 0.048)
Oil std. mm (in.) 2.01 – 2.03 (0.079 – 0.080)
1st std. mm (in.) 0.97 – 0.99 (0.038 – 0.039)
Piston ring thickness
2nd std. mm (in.) 1.17 – 1.19 (0.046 – 0.047)
std. mm (in.) 0.002 – 0.013 (0.0001 – 0.0005)
Pin clearance in piston pin hole
Limit mm (in.) 0.05 (0.0020)
std. mm (in.) 15.995 – 16.000 (0.6297 – 0.6299)
Piston pin outside diameter
Limit mm (in.) 15.980 (0.6291)
std. mm (in.) 16.002 – 16.008 (0.6300 – 0.6302)
Piston pin hole diameter
Limit mm (in.) 16.030 (0.6311)
std. mm (in.) 0.006 – 0.019 (0.0002 – 0.0007)
Pin clearance in conrod small end
Limit mm (in.) 0.050 (0.0020)

Crankshaft / Conrod
Data
Item Unit
DF25A DF30A
Conrod small end inside diameter std. mm (in.) 16.006 – 16.014 (0.6302 – 0.6304)
std. mm (in.) 0.025 – 0.049 (0.0010 – 0.0019)
Conrod big end oil clearance
Limit mm (in.) 0.080 (0.0031)
Conrod big end inside diameter std. mm (in.) 29.025 – 29.034 (1.1427 – 1.1431)
Crank pin outside diameter std. mm (in.) 28.985 – 29.000 (1.1411 – 1.1417)
Crank pin outside diameter
Limit mm (in.) 0.010 (0.0004)
difference (out-of-round and taper)
std. mm (in.) 0.100 – 0.250 (0.0039 – 0.0098)
Conrod big end side clearance
Limit mm (in.) 0.350 (0.0138)
Conrod big end width std. mm (in.) 19.950 – 20.000 (0.7854 – 0.7874)
Crank pin width std. mm (in.) 20.100 – 20.200 (0.7913 – 0.7953)
Crankshaft journal runout Limit mm (in.) 0.040 (0.002)
std. mm (in.) 0.020 – 0.051 (0.0008 – 0.0020)
Crankshaft journal oil clearance
Limit mm (in.) 0.080 (0.0031)
Crankcase bearing holder inside
std. mm (in.) 35.000 – 35.008 (1.3780 – 1.3783)
diameter
Crankshaft journal outside diameter std. mm (in.) 31.985 – 32.000 (1.2592 – 1.2598)
Crankshaft journal outside diameter
Limit mm (in.) 0.010 (0.0004)
difference (out-of-round and taper)
Crankshaft bearing thickness std. mm (in.) 1.486 – 1.490 (0.0585 – 0.0587)
std. mm (in.) 0.15 – 0.20 (0.006 – 0.009)
Crankshaft thrust play
Limit mm (in.) 0.35 (0.014)
 General Information: 0A-14

Electrical
Data
Item Unit
DF25A DF30A
Degrees at
Ignition timing 0° ± 7° BTDC – 25° BTDC
r/min
Over revolution limiter r/min 6 200 6 400
CKP sensor resistance Ω at 20 °C 168 – 252
CMP sensor resistance Ω at 20 °C —
ECM power source coil resistance Ω at 20 °C 1.1 – 1.7
Primary Ω at 20 °C 0.17 – 0.23
Ignition coil resistance
Secondary kΩ at 20 °C 4.8 – 7.2
Spark plug cap resistance kΩ at 20 °C 8 – 12
Battery charge coil resistance Ω at 20 °C 0.4 – 0.6
Battery charge coil output (12 V) W 168
Type NGK CPR6EA-9
Standard spark plug
Gap mm (in.) 0.8 – 0.9 (0.031 – 0.035)
Main: 30 (Electric start model)
Fuse amp. rating A
ECM: 10 (Remote control model)
Recommended battery capacity (12 V) Ah (kC) 70 (252) or large
Fuel injector resistance Ω at 20 °C 10 – 14
IAC valve resistance Ω at 20 °C 22 – 26
Cylinder temp. sensor (Thermistor
kΩ at 25 °C 10.0 – 11.5
characteristic)
IAT sensor (Thermistor characteristic) kΩ at 25 °C 1.8 – 2.3
Starter motor relay coil resistance Ω at 20 °C 4.2 – 4.6

Starter Motor
Data
Item Unit
DF25A DF30A
Max. continuous time of use Sec. 30
Motor output kW 0.6
std. mm (in.) 12.5 (0.49)
Brush length
Limit mm (in.) 9.0 (0.35)
std. mm (in.) 0.5 – 0.8 (0.020 – 0.030)
Commutator undercut
Limit mm (in.) 0.2 (0.01)
std. mm (in.) 30.0 (1.18)
Commutator outside diameter
Limit mm (in.) 29.0 (1.14)

PTT Motor
Data
Item Unit
DF25A DF30A
std. mm (in.) 9.8 (0.39)
Brush length
Limit mm (in.) 4.8 (0.19)
std. mm (in.) 19.5 (0.77)
Commutator outside diameter
Limit mm (in.) 18.5 (0.73)
0A-15 General Information:

Self-Diagnostic Code
0: OFF, 1: ON
Priority Failed item Code Lamp flashing pattern Fail-Safe system active
1

1 MAP sensor 1 3–4 0

Yes
MCODE00D34-0-01
1

2 Cylinder temp. sensor 1–4 0

Yes
MCODE00D14-0-01
1

3 IAT sensor 2–3 0

Yes
MCODE00D23-0-01
1

4 CKP sensor 4–2 0

No
MCODE00D42-0-01
1

5 CMP sensor 2–4 0

No
MCODE00D24-0-01
1

6 Air intake system 2–2 0

Yes
MCODE00D22-0-01
1

7 MAP sensor 2 3–2 0

No
MCODE00D32-0-01
1

8 Fuel injector 4–3 0

No
MCODE00D43-0-01
1

9 Throttle position sensor 2–1 0

Yes
MCODE00D21-0-01
1
Rectifier / Regulator
10 1–1 No
(Over-charging) 0
MCODE00D11-0-01
1
Oil pressure switch
11 5–3 No
(Remote control model) 0
MCODE00D53-0-01
 General Information: 0A-16

Tightening Torque Specifications

CENFL3120107003
NOTICE
Failure to use the correct fasteners or to properly use fasteners can cause parts or system damage.
• When fasteners are removed, always reinstall them at the locations from which they were removed.
• All fasteners must be replaced with fasteners having the same part number.
If a fastener of the correct part number is not available, a fastener of the same size having equal or
higher strength may be used.

Important Fasteners
Thread Tightening torque
Item
diameter N⋅m kgf-m lbf-ft
Cylinder head cover bolt 6 mm 10 1.0 7.2
Cylinder head bolt 8 mm 30 3.0 22.0
Inside 8 mm 28 2.8 20.0
Crankcase bolt
Outside 6 mm 11 1.1 8.0
Conrod cap bolt 6 mm 10 1.0 7.2
Rocker arm shaft bolt 6 mm 6 0.6 4.3
Valve adjusting screw lock nut 5 mm 11 1.1 8.0
Intake manifold bolt/nut 8 mm 23 2.3 16.5
Exhaust manifold bolt 8 mm 23 2.3 16.5
Oil pressure regulator 14 mm 27 2.7 19.5
Throttle body mounting bolt 6 mm 11 1.1 8.0
Low pressure fuel pump bolt 6 mm 11 1.1 8.0
Thermostat cover bolt 6 mm 11 1.1 8.0
Flywheel nut 14 mm 100 10.0 72.5
Camshaft pulley bolt 8 mm 30 3.0 22.0
Crankshaft timing pulley nut 27 mm 50 5.0 36.0
8 mm 23 2.3 16.5
Starter motor mounting bolt
6 mm 11 1.1 8.0
Power unit mounting bolt 8 mm 23 2.3 16.5
Driveshaft housing bolt 8 mm 23 2.3 16.5
Engine oil drain plug 12 mm 13 1.3 9.5
Oil pump bolt 6 mm 11 1.1 8.0
Engine oil filter — 14 1.4 10.0
Oil pressure switch — 13 1.3 9.5
Clamp bracket shaft nut 7/8-14 UNF 43 4.3 31.0
Upper mount cover bolt 8 mm 23 2.3 16.5
Upper mount nut 10 mm 40 4.0 29.0
Lower mount cover bolt 8 mm 23 2.3 16.5
Tiller handle cover bolt 8 mm 23 2.3 16.5
Water pump case nut 6 mm 6 0.6 4.3
Gearcase bolt 8 mm 23 2.3 16.5
Driveshaft oil seal housing — 50 5.0 36.0
Propeller shaft bearing housing bolt 6 mm 10 1.0 7.2
Pinion nut 8 mm 18 1.8 13.0
Propeller nut 14 mm 25 2.5 18.0
0A-17 General Information:

General Bolt

NOTE
These value are only applicable when torque for a general bolt is not listed in the “Important
Fasteners” table.

Thread Tightening torque

Type of bolt
diameter N⋅m kgf-m lbf-ft
5 mm 2–4 0.2 – 0.4 1.5 – 3.0
6 mm 4–7 0.4 – 0.7 3.5 – 5.0
8 mm 10 – 16 1.0 – 1.6 7.0 – 11.5
I9J011010014-01
10 mm 22 – 35 2.2 – 3.5 16.0 – 25.5
(Conventional or “4” marked bolt)
5 mm 2–4 0.2 – 0.4 1.5 – 3.0
6 mm 6 – 10 0.6 – 1.0 4.5 – 7.0
8 mm 15 – 20 1.5 – 2.0 11.0 – 14.5
I9J011010015-01
10 mm 34 – 41 3.4 – 4.1 24.5 – 29.5
(Stainless steel bolt)
5 mm 3–6 0.3 – 0.6 2.0 – 4.5
6 mm 8 – 12 0.8 – 1.2 6.0 – 8.5
8 mm 18 – 28 1.8 – 2.8 13.0 – 20.0
I9J011010016-01
10 mm 40 – 60 4.0 – 6.0 29.0 – 43.5
(“7” marked bolt)

Special Tools and Equipment

Recommended Service Material
CENFL3120108001

93691–80030 99000–22B22 99000–25011 99000–25350 99000–31140

SUZUKI Silicone Seal SUZUKI Outboard SUZUKI Super SUZUKI Water SUZUKI Bond 1207B
(100 g) Motor Gear Oil Grease A (450 g) Resistant Grease EP2 (100 g)
(250 g)

99000–32050 99000–22810
SUZUKI Thread Lock PTT Fluid
1342 (50 g)
 General Information: 0A-18

Special Tool
CENFL3120108002

01500–08403 09900–20101 09900–20202 09900–20203 09900–20205

Bolt Vernier calipers (150 Micrometer (25 – 50 Micrometer (50 – 75 Micrometer (0 – 25
mm) mm) mm) mm)

09900–20602 09900–20605 09900–20606 09900–20701 09900–20803

Dial gauge Dial calipers (10 – 34 Dial gauge Magnetic stand Thickness gauge
mm)

09900–21304 09900–22301 09900–25008 09900–28403 09911–49310

Steel “V” block set Plastigauge (0.025 – Multi circuit tester set Hydrometer Crankshaft holder
0.076 mm)

09912–58432 09912–58442 09912–58490 09913–50121 09915–47341

Fuel pressure hose Fuel pressure gauge 3-way joint & hose Oil seal remover Oil filter wrench

09915–63311 09915–64512 09915–77311 09915–78211 09916–10911

Compression gauge Compression gauge Oil pressure gauge Oil pressure gauge Valve lapper
attachment adapter
0A-19 General Information:

09916–14510 09916–14521 09916–34542 09916–34570 09916–37320

Valve lifter Valve lifter attachment Valve guide reamer Valve guide reamer (ø Valve guide reamer (ø
handle 5.0 mm) 10.5 mm)

09916–44310 09916–77310 09916–84511 09917–14910 09917–47011

Valve guide remover Piston ring Tweezers Valve adjustment Vacuum pump gauge
compressor driver

09919–19910 09921–29511 09922–59410 09922–59420 09922–89810

Deep socket wrench Driveshaft holder Propeller shaft Housing installer Shift lock pin remover
(8 mm) housing installer handle

09923–73210 09926–29400 09930–30104 09930–39411 09930–39420

Bearing remover Driveshaft oil seal Sliding hammer Flywheel remover Flywheel remover
housing remover bolts

09930–48720 09930–49211 09930–76310 09930–89260 09930–89290

Flywheel holder Flywheel holder Timing light Injector test cord (A) 18 pin & 34 pin test
attachment cord
 General Information: 0A-20

09933–08910 09945–79410 09950–59310 09950–69512 09950–69710

ECM power source PTT cable extension Propeller shaft Gearcase oil leakage Attachment
cable remover tester

09951–09530 09951–19440 09951–39914 09951–59910 09952–99320

Gear adjusting gauge Attachment Plate Shaft (removal and Hand air pump
installation)

Stevens peak reading

voltmeter CD-77
0B-1 Maintenance and Tune-Up:

Maintenance and Tune-Up

General Information

Precautions
Precautions for Maintenance
CENFL3120200001
The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work
necessary to keep the motor operating at peak performance and economy.
Maintenance intervals should be judged by number of hours or months, whichever comes first.

NOTE
More frequent servicing should be performed on outboard motors that are used under severe
conditions.

General Description
Recommended Oil and Lubricants
CENFL3120201001
Refer to “Fuel and Oil Recommendations” in Section 0A (Page 0A-4).

Scheduled Maintenance
Periodic Maintenance Schedule Chart
CENFL3120205001
NOTE
I = Inspect and clean, adjust, lubricate or replace, if necessary
T = Tighten
R = Replace

Interval
Item to be serviced Initial 20 hrs. or 1 Every 100 hrs. or Every 200 hrs. or Every 300 hrs. or
month 12 months 12 months 36 months
Spark plug — I — —
Breather hose and fuel line I I — —
Engine oil R R — —
Gear oil R R — —
Lubrication I I — —
Anodes (external) I I — —
Anodes (internal powerhead) — I — —
Bonding wires I I — —
Battery I I — —
Engine oil filter R — R —
I I — —
Low pressure fuel filter
Replace every 400 hours or 2 years.
In-line fuel filter Replace every 1 000 hours.
— — I —
Timing belt
Replace every 4 years.
Ignition timing — — I —
Idle speed I — I —
Valve clearance I — I —
Thermostat — I — —
Air cleaner element — — I —
Water pump — — I —
Water pump impeller — — I R
Propeller nut and pin I I — —
Bolt and Nuts T T — —
 Maintenance and Tune-Up: 0B-2

Lubrication Point
CENFL3120205002
Proper lubrication is important for the safe, smooth operation and long life of each working part of the outboard motor.
Apply Suzuki Water Resistant Grease to the following point.
Lubricate
Initially after 20 hours (1 month) and every 100 hours (12 months)
: Grease 99000–25350 (SUZUKI Water Resistant Grease EP2 (250 g))

IFL311020007-04

1. Throttle cable 3. Grease nipple, swivel bracket 5. Grease nipple, steering bracket
2. NSI cable 4. Clamp screw 6. Propeller shaft
0B-3 Maintenance and Tune-Up:

Service Instructions
Engine Oil Level Check
CENFL3120206001

Inspect oil level

Before every use
1) Place outboard motor upright on a level surface.
2) Remove motor cover.
3) Remove oil level dipstick (1) and wipe it clean.

IFL311020015-02

Engine Oil Change and Engine Oil Filter

Replacement
1 CENFL3120206002

Change engine oil

IFL311020008-01
Initially after 20 hours (1 month) and every 100 hours
(12 months)
4) Reinsert dipstick fully into dipstick tube, then remove
it to check oil level. Replace engine oil filter
5) Oil level should be between full level Max. mark Initially after 20 hours (1 month) and every 200 hours
(hole) and low level Min. mark (hole). (12 months)
If level is low, add recommended oil to full level Max. NOTE
mark.
• Engine oil should be changed while engine
Recommended engine oil
is warm.
• 4 stroke motor oil
• When replacing engine oil filter, change
• NMMA certified FC-W oil. engine oil at the same time.
or API classification:
SG, SH, SJ, SL, SM. Engine Oil Change
• Viscosity rating: 1) Place outboard motor upright on a level surface.
SAE 10W-40 or 10W-30, 2) Remove oil filler cap (1).
NMMA FCW 10W-40 or 10W-30.

“A”

“B”
IFL311020009-02
IFL311020011-01
“A”: Max. mark (hole) “B”: Min. mark (hole)
 Maintenance and Tune-Up: 0B-4

3) Place a container under engine oil drain plug. 6) Pour recommended engine oil into oil filler opening,
4) Remove engine oil drain plug (2) and gasket (3) to then install oil filler cap.
drain engine oil. Recommended engine oil
• 4 stroke motor oil
• NMMA certified FC-W oil.
or API classification:
SG, SH, SJ, SL, SM.
• Viscosity rating:
SAE 10W-40 or 10W-30,
NMMA FCW 10W-40 or 10W-30.
Engine oil amounts
Oil change only: 1.5 L (1.6/1.3 US/Imp. qt)
Oil filter change: 1.7 L (1.8/1.5 US/Imp. qt)
IFL311020012-01

2
3

IFL311020013-02
IFL311020015-02
5) Install new gasket and oil drain plug. 7) Reset oil change reminder system’s operation time
Tighten engine oil drain plug to specified torque. to zero (cancellation).
NOTICE NOTE
A previously-used gasket may leak, resulting Refer to “Oil Change Reminder System
in engine damage. Description” in Section 1A (Page 1A-14).
To avoid water entry into oil pan or oil 8) Start engine and allow it to run for several minutes at
leakage into the environment do not reuse idle speed.
gasket once removed. Check oil drain plug for oil leakage.
Always use a new one. Turn off engine and wait for approx. two minutes,
then recheck engine oil level.
Tightening torque
Engine oil drain plug (a): 13 N·m (1.3 kgf-m, 9.5
lbf-ft)

(a)

IFL311020014-02
0B-5 Maintenance and Tune-Up:

Engine Oil Filter Replacement 4) Screw the new filter on by hand until filter O-ring
1) Drain engine oil in the same manner of engine oil contacts the mounting surface.
change procedure. 5) Tighten the filter 3/4 turn from the point of contact
2) Place a shop cloth under the oil filter before removal with mounting surface using an oil filter wrench.
to absorb any oil released. Tightening torque
3) Using an oil filter wrench to loosen the oil filter, then Engine oil filter (a): 14 N·m (1.4 kgf-m, 10.0 lbf-ft)
remove the filter and O-ring.
Special tool
(A): 09915–47341 (Oil filter wrench)

(a)

(A)

IFL311020017-01

6) Pour the recommended engine oil into the oil filler

(A) opening, then install oil filler cap. Check the oil level
IFL311020016-01
in the same manner of engine oil change procedure.

NOTE Recommended engine oil

• 4 stroke motor oil
Before fitting a new oil filter, be sure to oil the
O-ring. • NMMA certified FC-W oil.
or API classification:
SG, SH, SJ, SL, SM.
• Viscosity rating:
SAE 10W-40 or 10W-30,
NMMA FCW 10W-40 or 10W-30.
Engine oil amounts
Oil change only: 1.5 L (1.6/1.3 US/Imp. qt)
Oil filter change: 1.7 L (1.8/1.5 US/Imp. qt)
7) Reset oil change reminder system’s operation time
to zero (cancellation).
I9J011020004-01 NOTE
Refer to “Oil Change Reminder System
Description” in Section 1A (Page 1A-14).

8) Start engine and allow it to run for several minutes at

idle speed.
Check oil filter for oil leakage.
Turn off engine and wait for approx. two minutes,
then recheck engine oil level.
 Maintenance and Tune-Up: 0B-6

Gear Oil Change NOTE

CENFL3120206003
To avoid a possible low gear oil level,
Change gear oil recheck gear oil level 10 minutes after doing
Initially after 20 hours (1 month) and every 100 hours procedure in step 8. If oil level is low, add
(12 months) additional gear oil until level is correct.
1) Place outboard motor upright on a level surface.
2) Raise the outboard motor in full tilt up position. Spark Plug Removal and Installation
CENFL3120206004
3) Place a container under the lower unit.
4) Remove lower gear oil drain plug (1) first, then Inspect spark plug
remove gear oil level plug (2) and drain gear oil. Every 100 hours (12 months)
Standard spark plug
NGK CPR6EA-9

NOTICE
Non-resistor types of spark plugs will
interfere with the function of the electronic
ignition, causing misfiring, or causing
problems with other electronic boat
2
equipment and accessories.

Only resistor (R) type spark plugs must be

used with this engine.
1
IFL311020018-01
Removal
5) Lower the motor in full trim down (upright) position.
6) With the outboard motor in a vertical position, fill with ! WARNING
recommended gear oil through oil drain hole until oil
The hot engine can burn you.
just starts to flow out from oil level hole.
Recommended gear oil Wait until the engine is cool enough to touch.
• Suzuki Outboard Motor Gear Oil or API
classification GL-5, Viscosity rating SAE #90 1) Disconnect the spark plug caps (1).
Hypoid gear oil.
Gear oil amount
330 ml (11.1/11.6 US/Imp. oz)

Arial
IFL311020020-03

2) Remove the spark plug with spark plug wrench.

IFL311020019-02

7) Install oil level plug before removing oil filler tube

from drain hole.
8) Install oil drain plug.

NOTICE
An used gasket may leak and allow water to
enter the gearcase causing severe damage.

Do not reuse gaskets once removed.

Always use a new gaskets.
IFL311020021-01
0B-7 Maintenance and Tune-Up:

Installation
Installation is reverse order of removal.
Pay attention to the following:
• Tighten the spark plug to specified torque.
Tightening torque
Spark plug (a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)

IAJ311020006-01

Spark Plug Gap

Measure spark plug gap with a thickness gauge. Adjust
to within specified range if gap is out of specification.
Special tool
(a) : 09900–20803 (Thickness gauge)
Spark plug gap “a”
Standard: 0.8 – 0.9 mm (0.031 – 0.035 in.)
IFL311020022-01

Spark Plug Inspection and Cleaning

CENFL3120206005
NOTICE
Non-resistor types of spark plugs will
interfere with the function of the electronic
ignition, causing misfiring, or causing
problems with other electronic boat “a”
equipment and accessories.
I9J011020007-01
Only resistor (R) type spark plugs must be
used with this engine.
Condition of Electrodes
Inspect spark plug Inspect electrode for a worn or burnt condition.
Every 100 hours (12 months) If it is extremely worn or burnt, replace spark plug.
Also, be sure to replace spark plug if it has a broken
Standard spark plug insulator, damaged thread, etc.
NGK CPR6EA-9
NOTICE
Carbon Deposits
Inspect for carbon deposits on spark plug base. Use of improper spark plugs can cause
If carbon is present, remove it with a spark plug cleaning severe engine damage.
machine or by carefully using a pointed tool. If the reach is too short, carbon will be
deposited on the threaded portion of the plug
hole resulting in possible engine damage.

Confirm the thread size and reach when

replacing the plug.

I9J011020005-01
 Maintenance and Tune-Up: 0B-8

Valve Clearance Inspection and Adjustment

CENFL3120206006

Inspect valve clearance

Initially after 20 hours (1 month) and every 200 hours “B”
(12 months) “A”
Inspection
1) Remove following parts:
• Engine lower side cover.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
• Recoil starter. IFL311020024-01
Refer to “Recoil Starter Removal and Installation” “A”: Punch mark (○) “B”: INDEX mark
in Section 1J (Page 1J-3).
• Spark plugs. NOTE
Refer to “Spark Plug Removal and Installation”
(Page 0B-6). • The piston must be at its TDC position on a
compression stroke to check or adjust
2) Remove the cylinder head cover (1).
valve clearance.
Refer to “Cylinder Head Cover Removal and
Installation” in Section 1D (Page 1D-3). • The valve clearance specification is for
COLD engine condition.
• The valve clearance specification is
different for the intake (IN) valves and the
1 exhaust (EX) valves.

4) Measure valve clearances by inserting the thickness

gauge between valve stem end and valve adjusting
screw on rocker arm.
Special tool
(A): 09900–20803 (Thickness gauge)
Valve clearance (cold engine condition):
IFL311020023-01
IN.: 0.18 – 0.22 mm (0.007 – 0.009 in.)
NOTICE EX.: 0.20 – 0.24 mm (0.008 – 0.009 in.)
Turning of the engine in counterclockwise
can cause water pump impeller damage.

Rotate the crankshaft in the normal running

direction only (clockwise) to prevent water
pump impeller damage.

3) Rotate the flywheel clockwise to bring each piston to

Top Dead Center (TDC) on compression stroke.
(A)
Align each PUNCH mark on cam pulley with INDEX
mark on cylinder head block.
Punch mark TDC cylinder number IFL311020025-01

I No.1 cylinder
II No.2 cylinder 2 1
III No.3 cylinder
4

IFL311020005-02

1. Lock nut 3. Valve stem

2. Valve adjusting screw 4. Valve clearance
0B-9 Maintenance and Tune-Up:

5) If measurement is out of specification, adjust valve Tightening torque

clearance. Cylinder head cover bolts (b): 10 N·m (1.0
kgf-m, 7.2 lbf-ft)
Adjustment
1) Loosen valve adjusting lock nut (1).
2) Turn valve adjusting screw (2) using the valve
adjustment driver to bring valve clearance to within
specification.
Special tool (b)
(A): 09900–20803 (Thickness gauge)
(B): 09917–14910 (Valve adjustment driver)

1 2 IFL311020059-02

(B)

(A) (b)

IFL311020001-02

3) Tighten valve adjusting lock nut while holding valve

adjusting screw.
Tightening torque IFL311020027-01

Valve adjusting lock nut (a): 11 N·m (1.1 kgf-m, b) Final assembly check
8.0 lbf-ft) • All parts removed have been returned to their
original positions.
• Check wire and hose routing.
Refer to “Fuel/Water Hose Routing” in Section
(a) 4B (Page 4B-1) and “Wiring Harness Routing
Diagram” in Section 4A (Page 4A-7).
• Check oil leakage.

Timing Belt Inspection

CENFL3120206007

Inspect timing belt

IFL311020026-01
Every 200 hours (12 months)
4) Recheck valve clearance. If wear, cracks or other damage is found, replace the
5) After checking and adjusting all valves, reinstall parts timing belt.
removed earlier.
Installation is reverse order of removal.
a) Cylinder Head Cover Installation
• Install the cylinder head cover.
Refer to “Cylinder Head Cover Removal and
Installation” in Section 1D (Page 1D-3).

NOTICE
A previously-used gasket may leak, resulting 1
in engine damage.

IFL311020028-02
Do not re-use gasket once removed. Always
use a new one. 1. Timing belt
 Maintenance and Tune-Up: 0B-10

Timing Belt Replacement 5) Disconnect cylinder temp. sensor lead wire

CENFL3120206008 connector.
Replace timing belt
Every 4 years
1) Remove the recoil starter.
Refer to “Recoil Starter Removal and Installation” in
Section 1J (Page 1J-3).
2) Remove the bolt and cam pulley cover (1).

IFL311020032-01

6) Remove the three bolts securing battery charge coil

(3).

IFL311020029-01

3) Remove the spark plugs.

Refer to “Spark Plug Removal and Installation”
(Page 0B-6).
4) Remove the flywheel (2).
Refer to “Flywheel Removal and Installation” in 3
Section 1K (Page 1K-4).
Special tool IFL311020033-01

(A): 09930–48720 (Flywheel holder) 7) Lift battery charge coil from cylinder block and lay it
(B): 09930–49211 (Flywheel holder as shown figure.
attachment)
(C): 09930–39411 (Flywheel remover)
(D): 09930–39420 (Flywheel remover bolts)

(B)

(A)

IFL311020034-01
2
NOTICE
IFL311020030-02 Turning of the engine in counterclockwise
can cause water pump impeller damage.

Rotate the crankshaft in the normal running

(D)
(C)
direction only (clockwise) to prevent water
pump impeller damage.

IFL311020031-02
0B-11 Maintenance and Tune-Up:

8) Turn the crankshaft clockwise until No.1 piston

reaches at Top Dead Center on compression stroke.

NOTE
To set No.1 piston at Top Dead Center on 5
compression stroke:
Align the punch mark on the timing pulley
nut lock washer (3) with the INDEX mark on
the cylinder block when punch mark of “I” on
the cam pulley aligns with the INDEX mark on
the cylinder head as shown in the illustration.
IFL311020036-01
Special tool
(E): 09911–49310 (Crankshaft holder) NOTE

2 • Do not rotate the crankshaft or the cam

pulley before installing the belt; the
following must be checked:
– The PUNCH mark on the timing pulley
1
aligns with the INDEX mark on the
cylinder block.
– The PUNCH mark of “I” on the cam
pulley aligns with the INDEX mark on the
cylinder head block.
• If the timing pulley or the cam pulley is
IFL311020003-02 rotated with the timing belt removed or
1. PUNCH mark (○) on can pulley 2. INDEX mark on cylinder head
installed but misaligned, this may cause
the valves to become bent. If the alignment
marks are not correctly matched, loosen
(E)
the valve adjusting screw lock nuts and the
valve adjusting screws fully to prevent
valve damage.
Then align the marks correctly by rotating
3
the cam pulley clockwise.
• If it is necessary to rotate the camshaft
after removing timing belt, turn crankshaft
clockwise and position the flywheel key (6)
within an angle of 45° to 60° from TDC
before rotating the camshaft as shown in
4 the following figure and keep the valves
IFL311020035-03
from coming in contact with the pistons.
3. Punch mark on timing pulley nut lock washer.
4. INDEX mark on cylinder block

NOTICE 6

After the timing belt has been removed,

independently turning cam pulley or
crankshaft will cause interference between
piston and valve, which cause damage to
these related parts.

Do not rotate the cam pulley and/or “a”

crankshaft with timing belt removed.
IFL311020062-02

9) Remove the timing belt (5) from the cam pulley first, 6. Flywheel key “a”: 45° – 60°

then from the timing pulley.

10) Install the timing belt on the timing pulley first, then
the cam pulley.
 Maintenance and Tune-Up: 0B-12

NOTICE 12) Install the battery charge coil, then tighten bolts
Grease, oil or any similar material will securely.
damage the timing belt.

Always keep the timing belt away from any

grease and oil.

NOTE
The timing belt must be installed with the
arrow mark on the timing belt toward the
direction of rotation.

IFL311020040-01

13) Install the following parts.

a) Flywheel.
Refer to “Flywheel Removal and Installation” in
Section 1K (Page 1K-4).
Special tool
(A): 09930–48720 (Flywheel holder)
(B): 09930–49211 (Flywheel holder
attachment)

IFL311020037-01 Tightening torque

11) Make sure that the PUNCH mark of “I” on the cam Flywheel nut (a): 100 N·m (10 kgf-m, 72.5 lbf-
pulley aligns with the INDEX mark on the cylinder ft)
head block when the PUNCH mark on the timing
pulley nut lock washer aligns with the INDEX mark (B)
on the cylinder block.
(A)

1
(a)

IFL311020041-02

b) Recoil starter.
Refer to “Recoil Starter Removal and Installation”
IFL311020038-02 in Section 1J (Page 1J-3).
c) Spark plugs.
Refer to “Spark Plug Removal and Installation”
(Page 0B-6).
d) Lower side covers.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
3
14) Final assembly check.
4 • All parts removed have been returned their
original positions.
• Check wire and hose routing.
Refer to “Wiring Harness Routing Diagram” in
IFL311020060-01
Section 4A (Page 4A-7) and “Fuel/Water Hose
1. Punch mark on cam pulley Routing” in Section 4B (Page 4B-1).
2. INDEX mark on cylinder head
3. Punch mark on timing pulley nut lock washer
4. INDEX mark on cylinder block
0B-13 Maintenance and Tune-Up:

Idle Speed and Idle Air Control (IAC) Duty Inspection

Inspection 1) Connect the engine tachometer lead wires as
CENFL3120206009
follows;
Inspect idle speed and IAC duty a) Yellow lead wire to the Yellow/Black lead wire of
Initially after 20 hours (1 month) and every 200 hours engine main harness.
(12 months)
b) Gray lead wire to DC 12 V power source positive
NOTE terminal.
Before checking idle speed/IAC duty, make c) Black lead wire to DC 12 V power source
sure of the following. negative terminal and engine body ground.
Special tool
• Engine must be warmed up.
: 34200-93J32 (Engine tachometer)
• Check idle speed after engine speed has
stabilized. NOTE
• Check throttle link mechanism and throttle Check and/or adjust the idle speed after the
valve for smooth operation. engine speed has stabilized.
• Lead wire and hoses of electronic fuel
injection and engine control systems are
connected securely. 1

• Ignition timing is within specification.

• Valve clearance is checked according to
maintenance schedule.
• No abnormal air drawn in from air intake
system.
After all items are confirmed, check idle
speed.

2 Y
Y/B
B

Gr

3
IFL311020004-03

1. ECM 2. Main harness 3. Battery

2) Start engine and allow to warm up.

3) Check engine idle speed.
Idle speed in neutral gear (IAC duty)
800 – 900 r/min. (Duty: Approx. 10%)
 Maintenance and Tune-Up: 0B-14

Adjustment
If the idle speed is out of specification, adjust it as
follows:

NOTE
Idling/trolling speed is controlled by IAC
system.
Do not attempt to adjust the throttle valve
opening such as by turning the throttle stop
screw. IDK111020054-01

1) Shift into neutral and close the throttle fully.

2) To set the IAC valve duty in 10% constantly, raise
engine speed above 1 100 r/min. by turning the by-
pass air screw (1) and hold the engine speed for 10
seconds. 1
The “Check Engine” lamp will flash and notify you
that the IAC duty is in fixed mode.

Turning air screw counterclockwise:

Engine speed will increase.
Turning air screw clockwise: IFL311020042-02
Engine speed will decrease.
3) During this fixed mode, adjust engine speed to 850 ±
NOTE 50 r/min by turning by-pass air screw.
The IAC duty will not shift to a fixed mode, if 4) When finished adjusting the idle speed, opening the
engine warm-up is insufficient. throttle will cancel the (IAC) fixed mode.
5) Return the throttle to fully close and check engine
NOTE speed.
It should now be stable at 800 – 900 r/min.
Detach the by-pass air screw from the throttle
body if the system doesn’t shift into the IAC NOTE
fixed mode even loosening the screw.
Trolling speed (in-gear) is same as idle
Re-install the by-pass air screw on the
speed.
throttle body when the system is shifted into
the IAC fixed mode.
NOTE
Then adjust the IAC duty by the by-pass air
screw. The fixed mode of IAC can also be canceled
manually by shifting to Forward or Reverse
NOTE or raising the engine speed (changes the TPS
full close throttle signal to OFF).
• While IAC valve duty is at a fixed 10% duty,
the “Check Engine” lamp will flash. NOTE
• On the remote control models;
Idling/trolling speed of 800 – 900 r/min. is
While IAC valve duty is at a fixed 10% duty,
controlled by IAC (idle air control) system.
the caution buzzer will sound in a
If engine speed does not return to
repeating pattern of 0.5 second on with an
specification, IAC passage may be clogged
interval of 3 seconds off. This function is
or IAC system may not be operating
added to the “Check Engine lamp
correctly.
flashing”.
• The 10% fixed mode of IAC valve duty will
continue for 5 minutes after which it will
automatically cancel.
0B-15 Maintenance and Tune-Up:

Ignition Timing Inspection

CENFL3120206010 1
Inspect ignition timing
Every 200 hours (12 months)

NOTE
Before checking the ignition timing, make
sure idle speed is adjusted within
specification.

1) Connect the engine tachometer lead wires as

follows;
2 Y
a) Yellow lead wire to the Yellow/Black lead wire of Y/B
B
engine main harness.
b) Gray lead wire to DC 12 V power source positive
terminal. Gr
c) Black lead wire to DC 12 V power source
negative terminal and engine body ground.
3
2) Start the engine and allow to warm up.
IFL311020004-03
3) Attach the timing light cord to the ignition coil No.1
1. ECM 2. Main harness 3. Battery
cylinder high-tension cord.
Special tool
(A): 09930–76310 (Timing light) (A)

: 34200-93J32 (Engine tachometer)

IFL311020043-02

4) Check the ignition timing while operating the engine

in neutral gear at 1 000 r/min.
Ignition timing
Approx. 0° BTDC at 1 000 r/min.
 Maintenance and Tune-Up: 0B-16

Breather Line and Fuel Line Inspection

CENFL3120206011

Inspect breather line and fuel line

Initially after 20 hours (1 month) and every 100 hours (12 months)
If leakage, cracks, swelling or other damage is found, replace the breather hose and/or fuel line.

Fuel line check point

IFL311020006-02
0B-17 Maintenance and Tune-Up:

Low Pressure Fuel Filter Inspection 3) Remove the fuel filter (3) from filter bracket (4).
CENFL3120206012
4) Remove the cap (5), then drain and clean fuel filter.
Inspect low pressure fuel filter 5) Install the cap, then secure it with clip (6).
Initially after 20 hours (1 month) and every 100 hours
(12 months)
Replace low pressure fuel filter
Every 400 hours or 2 years 4
If water accumulation, sediment, leakage, cracks or
other damage is found, replace the fuel filter.

6
3
5

IFL311020046-01

6) Install fuel filter to filter bracket properly.

7) Connect the fuel inlet and outlet hose to fuel filter,
1 then secure the fuel hose to the fuel filter with the
hose clip.
8) Restart the engine and check that there are no leaks
IFL311020044-01 around the fuel filter.
1. Low pressure fuel filter
In-line Fuel Filter Replacement
CENFL3120206013
! WARNING
Replace In-line fuel filter
Gasoline is extremely flammable and toxic. It Every 1 000 hours
can cause a fire and can be hazardous to
people and pets. This filter is located between fuel vapor separator and
high pressure fuel pump.
Always take the following precautions when SUZUKI recommends that replacing the in-line fuel filter
servicing the fuel filter: every 1 000 operating hours.
For in-line fuel filter replacement procedure, refer to “In-
• Stop the motor before cleaning the fuel line Fuel Filter Removal and Installation” in Section 1G
filter. (Page 1G-24).
• Be careful not to spill fuel. If you do, wipe it
up immediately.
• Do not smoke, and keep away from open
flames and sparks.

1) Turn the engine off.

2) Disconnect the inlet hose (1) and outlet hose (2)
from fuel filter (3).

1
2
IFL311020058-02

1. In-line fuel filter

1

IFL311020045-01
 Maintenance and Tune-Up: 0B-18

Water Pump and Water Pump Impeller Propeller / Propeller Nut and Cotter Pin
Inspection Inspection
CENFL3120206014 CENFL3120206015

Inspect water pump / pump impeller Inspect propeller / propeller nut and cotter pin
Every 200 hours (12 months) Initially after 20 hours (1 month) and every 100 hours
(12 months)
Replace water pump impeller
Every 300 hours (36 months) 1) Inspect propeller for bent, chipped or broken blades.
Replace propeller if damage noticeably affects
operation.
2) Remove the propeller.
Refer to “Propeller Removal and Installation” in
Section 3A (Page 3A-4).
3) Inspect propeller splines. Replace propeller if splines
are worn, damaged or twisted.
4) Inspect propeller bush for slippage.
Replace if necessary.

IFL311020047-01

1) Remove the lower unit and water pump case.

Refer to “Water Pump Removal and Installation” in
Section 3A (Page 3A-6).
2) Inspect water pump case, inner sleeve and under
panel. Replace if wear, cracks, distortion or corrosion
IFL311020048-03
is found.
3) Inspect water pump impeller.
Replace if vanes are cut, torn or worn.
SUZUKI recommends that replacing the water pump
impeller every 300 hours (36 months).
4) Assemble the water pump related items.
Refer to “Water Pump Removal and Installation” in
Section 3A (Page 3A-6).
5) Install the lower unit assembly.
Refer to “Lower Unit Removal and Installation” in
Section 3A (Page 3A-5).
IAJ311020056-01

5) Install the propeller and related parts.

Refer to “Propeller Removal and Installation” in
Section 3A (Page 3A-4).
6) Make sure that propeller nut is torqued to
specification and cotter pin is installed securely.
Tightening torque
Propeller nut: 25 N·m (2.5 kgf-m, 18.0 lbf-ft)
0B-19 Maintenance and Tune-Up:

Anodes Inspection
CENFL3120206016

Inspect anodes (external)

Initially after 20 hours (1 month) and every 100 hours
(12 months)
Inspect anodes (internal powerhead)
Every 100 hours (12 months)
If 2/3 of zinc anode has corroded away, replace anode.
The anode should be periodically cleaned with a wire
brush to ensure maximum effectiveness.
IFL311020049-02
NOTICE
If anodes are not properly maintained,
underwater aluminum surfaces (such as the
lower unit) will suffer galvanic corrosion
damage.
• Periodically inspect anodes to make sure
they have not become detached.
• Do not paint anodes, as this will render
them ineffective.
• Periodically clean anodes with a wire
brush to remove any coating which might
decrease their protective ability. IFL311020050-02

NOTE
The anode securing bolt should be covered
with Suzuki silicone seal.

: Sealant 93691–80030 (SUZUKI Silicone Seal

(100 g))

2
1

IFL311020061-01

Bonding Wire Inspection

CENFL3120206017

Inspect bonding wires

IAJ311020002-01 Every 100 hours (12 months)
If breakage or other damage is found on bonding wire,
1
2 replace the wire.
If rust, corrosion or other damage is found on terminal,
clean with cleaning solvent or replace the wire.

IAJ311020057-01

1. Anode 2. Bolt

IFL311020051-02
 Maintenance and Tune-Up: 0B-20

Battery Inspection Connecting Battery

CENFL3120206018

Inspect battery ! WARNING

Initially after 20 hours (1 month) and every 100 hours Battery posts, terminals, and related
(12 months) accessories contain lead and lead
compounds that may be hazardous.
! WARNING
Failure to take proper precautions when Wash hands after handling.
handling the battery may cause severe injury.
NOTICE
Be sure to take the following precautions
The electrical system or its components may
when handling the battery:
be damaged if proper battery precautions are
• Never expose the battery to open flames or not followed.
electric sparks as batteries generate gas
• Be sure to attach battery leads correctly.
which is flammable and explosive.
Wing nuts must not be used and hexagon
• Do not place the battery near the fuel tank. nuts must be used to secure battery cable
• Battery acid is poisonous and corrosive. to the battery terminals to avoid loss of
Avoid contact with eyes, skin, clothing, electrical power.
and painted surfaces. • Do not disconnect battery leads from the
If you come in contact with battery acid, battery while the engine is running.
flush immediately with large amounts of
water and seek immediate medical How to connect
attention. 1) Connect positive (+) terminal first.
• Batteries should always be kept out of 2) Connect negative (–) terminal second.
reach of children.
3) Upon completion of connection, lightly apply grease
• When checking or servicing battery, to battery terminals.
disconnect the negative (black) cable. Be
careful not to cause a short circuit by 1
allowing metal objects to contact the
battery posts and motor at the same time.
2
• Wear approved eye protection.

Recommended battery
12 V 70 AH (252 kC) or larger
Refer to “Battery Requirement” in Section 0A (Page 0A-
6). IAJ311020003-01

1. Red lead 2. Black lead

How to disconnect
1) Disconnect negative (–) terminal first.
2) Disconnect positive (+) terminal second.

IAJ311020004-01

1. Red lead 2. Black lead

0B-21 Maintenance and Tune-Up:

Battery Solution Level Check Thermostat Inspection

CENFL3120206019
NOTICE
Inspect thermostat
If you add diluted sulphuric acid to the Every 100 hours (12 months)
battery after it has been initially serviced, you
Inspect thermostat every 100 hours (12 months).
will damage the battery.
Refer to “Thermostat Removal and Installation” in
Section 1F (Page 1F-3) and “Thermostat and Related
NEVER add diluted sulphuric acid to the
Items Inspection” in Section 1F (Page 1F-4).
battery after it has been initially serviced.
Follow the battery manufacturer’s
instructions for specific maintenance Air Cleaner Element Inspection
CENFL3120206020
procedures.
Inspect air cleaner element
Battery solution level should be between UPPER level Every 200 hours (12 months)
and LOWER level.
Inspect the air cleaner element every 200 hours (12
If level is low, add distilled water only.
months).
Refer to “Air Cleaner Element Removal and Installation”
in Section 1D (Page 1D-2) and “Air Cleaner Element
Inspection” in Section 1D (Page 1D-2).

Bolts and Nuts Inspection

CENFL3120206021

Inspect bolts and nuts

I9J011020031-01
Initially after 20 hours (1 month) and every 100 hours
(12 months)
Battery Solution Specific Gravity Check Check that all bolts and nuts listed below are tightened
Measure the specific gravity of battery solution using a to their specified torque.
hydrometer. Refer to “Tightening Torque Specifications” in Section 0A
Battery solution specific gravity (temperature) (Page 0A-16).
1.28 (20 °C) • Cylinder head cover bolts
Special tool • Intake manifold bolts
: 09900–28403 (Hydrometer) • Flywheel nut
• Power unit mounting bolts
• Clamp bracket shaft nut
• Gearcase bolts
• Propeller nut

I9J011020032-01
 Maintenance and Tune-Up: 0B-22

Oil Pressure Check 3) Loosen screw and disconnect blue / yellow lead wire
CENFL3120206022 (2) from oil pressure switch (3).
! CAUTION Remove the oil pressure switch.
Engine oil can be hot enough to burn you.

Do not remove the oil pressure gauge

adapter when the engine is hot. Wait until 3
engine cools. 2

Check the engine oil pressure periodically.

1) Check the engine oil level.
2) Connect the engine tachometer lead wire as follows;
a) Yellow lead wire to the Yellow/Black lead wire of
engine main harness. IFL311020052-01
b) Gray lead wire to DC12 V power source positive 4) Install oil pressure gauge adaptor into oil pressure
terminal. switch hole in place of oil pressure switch.
c) Black lead wire to DC12 V power source
Special tool
negative terminal and engine body ground.
(A): 09915–77311 (Oil pressure gauge)
Special tool
(B): 09915–78211 (Oil pressure gauge
: 34200-93J32 (Engine tachometer)
adapter)
1

(A)

(B)

2 Y
Y/B IFL311020053-01
B

Gr

3
IFL311020004-03

1. ECM 2. Main harness 3. Battery

0B-23 Maintenance and Tune-Up:

5) Start engine and allow to warm up. Cylinder Compression Pressure Check
CENFL3120206023
NOTE The compression pressure reading of cylinder is good
indicator of its internal condition.
On the remote control model;
The decision to overhaul the power unit is often based
Because lead wire of oil pressure switch is
on the results of a compression test.
disconnected when testing the oil pressure,
Periodic maintenance records kept at your dealership
the diagnosis code of oil pressure switch will
should include compression readings for each
temporarily be displayed during the testing.
maintenance service.
6) After warming up, shift into forward gear and 1) Start engine and allow to warm up, then shut engine
increase engine speed to 3 000 r/min., then compare off.
pressure indicated on gauge to specifications. 2) Remove the STBD / PORT lower side cover.
Refer to “Lower Side Cover Removal and
NOTE
Installation” in Section 2A (Page 2A-3).
The figure shown below is a guideline only, 3) Remove all spark plugs.
not an absolute service limit.
4) Disconnect all fuel injector connectors (1) at fuel
Oil pressure injector.
200 – 500 kPa (2.0 – 5.0 kg/cm2, 28 – 71 psi.)
at 3 000 r/min., oil temp. at normal operating
temp.
7) If oil pressure is lower or higher than specification,
the following causes may be considered.
Low oil pressure
• Clogged oil filter 1
• Leakage from oil passages
• Defective oil pump
• Defective oil pressure regulator
IFL311020054-01
• Damage O-ring
5) Install compression gauge attachment into spark
• Combination of above items plug hole, then connect compression gauge
High oil pressure attachment to compression gauge.
• Using an engine oil of too high viscosity
Special tool
• Clogged oil passage (A): 09915–64512 (Compression gauge)
• Clogged oil pressure regulator (B): 09915–63311 (Compression gauge
• Combination of above items attachment)
8) After testing, reinstall oil pressure switch.
Refer to “Oil Pressure Switch Removal and (A)
Installation” in Section 1E (Page 1E-5).
9) Check the engine oil level.
(B)

IFL311020055-01
 Maintenance and Tune-Up: 0B-24

6) Disconnect the safety lanyard from the emergency 9) While cranking engine with starter motor or recoil
stop switch. starter, note maximum compression pressure
reading on gauge for each cylinder.
! WARNING
NOTE
If this test is performed without
disconnecting the safety lanyard from the Figures shown are guidelines only, not
emergency stop switch, a spark from a spark absolute service limits.
plug cap may ignite fuel vapor coming out of
the spark plug holes during the test, causing NOTE
a fire or explosion. Reading of the cylinder compression
pressure value will be affected by the
Be sure to disconnect the safety lanyard from decompression system.
emergency stop switch before performing When measure the cylinder compression
this test. value while cranking by the starting motor,
the reading will usually be 1 500 – 1 800 kPa.
In case of insufficient engine warm-up, the
engine oil temperature doesn’t reach to the
normal operating temperature, or using the
low capacity battery, the measurement of the
cylinder compression value will be the same
one as the case to do the cranking with the
recoil starter.

Cylinder compression pressure

Crank with recoil starter;
Standard: 500 – 1 000 kPa (5 – 10 kg/cm2, 71 –
142 psi.)
IFL311020056-02
Crank with starter motor;
7) Disconnect the remote control throttle cable from the Standard: 500 – 1 800 kPa (5 – 18 kg/cm2, 71 –
throttle lever (Remote control model). 256 psi.)
8) Move and hold throttle control grip in the full-open
Cylinder compression pressure max. difference
position. (Tiller handle model).
between cylinders
Move and hold the throttle lever in the full-open
100 kPa (1.0 kg/cm2, 14 psi.)
position (Remote control model).
Low compression pressure can indicate one or more
of following:
• Excessively worn cylinder wall
• Worn piston or piston rings
• Stuck piston rings
• Poor seating of valves
• Ruptured or otherwise damaged cylinder head
gasket
IDK111020070-02
10) Reinstall parts removed earlier (spark plugs, side
lower covers, etc.).

IFL311020057-01
0B-25 Maintenance and Tune-Up:
 Table of Contents 1- i

Section 1

Power Head
CONTENTS

Precautions .................................................1-1 Precautions...........................................................1C-1

Precautions............................................................. 1-1 Precaution for Engine Electrical Device ..............1C-1
Precautions for Powerhead................................... 1-1 General Description .............................................1C-1
Sensor and Switch Description ...........................1C-1
Engine Control......................................... 1A-1 ECM Power Source.............................................1C-4
Precautions...........................................................1A-1 Component Location ...........................................1C-4
Precautions on Engine Control Diagnosis........... 1A-1 Location of Sensor and Switch............................1C-4
General Description .............................................1A-2 Service Instructions .............................................1C-5
Engine Control System Description .................... 1A-2 Resistance Check ...............................................1C-5
Engine Control Module (ECM) ............................ 1A-5 ECM Power Source Input Voltage Inspection .....1C-6
Caution System Description................................ 1A-9 ECM Power Source Coil Removal and
Self-Diagnostic System Description .................. 1A-12 Installation .........................................................1C-6
Fail-Safe System Description............................ 1A-14 CKP Sensor Peak Voltage Inspection.................1C-6
Oil Change Reminder System Description........ 1A-14 CKP Sensor Removal and Installation ................1C-7
Component Location .........................................1A-16 Cylinder Temp. Sensor Removal and
Engine Control System Components / Engine Installation .........................................................1C-8
Electrical Device Location ............................... 1A-16 Cylinder Temp. Sensor Inspection ......................1C-9
Diagnostic Information and Procedures..........1A-16 IAT Sensor Removal and Installation..................1C-9
Troubleshooting with Self-Diagnostic Code ...... 1A-16 IAT Sensor Inspection.........................................1C-9
Self-Diagnostic Code “3 – 4” MAP Sensor........ 1A-16 CMP Sensor Removal and Installation .............1C-10
Self-Diagnostic Code “1 – 4” Cylinder Temp. CMP Sensor Inspection ....................................1C-10
Sensor............................................................. 1A-17 MAP Sensor Removal and Installation..............1C-11
Self-Diagnostic Code “2 – 3” IAT Sensor .......... 1A-18 MAP Sensor Output Voltage Inspection............1C-11
Self-Diagnostic Code “4 – 2” CKP Sensor ........ 1A-19 IAC Valve Removal and Installation..................1C-12
Self-Diagnostic Code “2 – 4” CMP Sensor........ 1A-20 IAC Valve Inspection.........................................1C-14
Self-Diagnostic Code “2 – 2” Air Intake TPS Inspection..................................................1C-14
System ............................................................ 1A-21 Emergency and Engine Stop Switch
Self-Diagnostic Code “3 – 2” MAP Sensor 2..... 1A-22 Inspection........................................................1C-15
Self-Diagnostic Code “4 – 3” Fuel Injector ........ 1A-24
Self-Diagnostic Code “2 – 1” TPS (Throttle
Power Unit Mechanical ........................... 1D-1
Position Sensor).............................................. 1A-25 General Description .............................................1D-1
Self-Diagnostic Code “1 – 1” Rectifier / Power Unit Construction Description ..................1D-1
Regulator (Over Charging).............................. 1A-26 Diagnostic Information and Procedures ............1D-1
Self-Diagnostic Code “5 – 3” Oil Pressure Cylinder Compression Check..............................1D-1
Switch ............................................................. 1A-27 Oil Pressure Check .............................................1D-1
Troubleshooting Without Self-Diagnostic Service Instructions .............................................1D-2
Code ............................................................... 1A-28 Valve Clearance Inspection ................................1D-2
IAC System Troubleshooting ............................ 1A-28 Recoil Starter Removal and Installation ..............1D-2
Service Instructions...........................................1A-29 Air Cleaner Element Removal and Installation ....1D-2
How to Use The 34 Pin Test Cord .................... 1A-29 Air Cleaner Element Inspection...........................1D-2
Inspection of The ECM and Its Circuit............... 1A-30 Cylinder Head Cover Removal and
ECM Removal and Installation.......................... 1A-34 Installation .........................................................1D-3
Caution Lamp Inspection .................................. 1A-34 Intake Manifold and Throttle Body
Components......................................................1D-5
Engine Electrical Devices ....................... 1C-1 Intake Manifold Removal and Installation ...........1D-6
1-ii Table of Contents

Throttle Body Removal and Installation ............1D-10 Water Tube Related Item Inspection................... 1F-5
Throttle Body Inspection ...................................1D-11
Camshaft Pulley / Crankshaft Timing Pulley / Fuel System ............................................. 1G-1
Timing Belt Removal and Installation..............1D-11 Precautions.......................................................... 1G-1
Power Unit Removal and Installation ................1D-15 Precautions on Fuel System Service ................. 1G-1
Camshaft, Rocker Arm and Rocker Arm Shaft General Description ............................................ 1G-2
Removal and Installation.................................1D-26 Electronic Fuel Injection System Description ..... 1G-2
Camshaft, Rocker Arm and Rocker Arm Shaft Fuel Delivery System Components
Inspection........................................................1D-29 Description ....................................................... 1G-4
Cylinder Head Assembly Components .............1D-31 High Pressure Fuel Pump Control System
Cylinder Head Removal and Installation ...........1D-32 Description ....................................................... 1G-6
Cylinder Head Disassembly and Assembly ......1D-33 Air Intake Components Description.................... 1G-7
Cylinder Head Components Inspection and Idle Air Control System Description ................... 1G-9
Servicing .........................................................1D-35 Diagnostic Information and Procedures ......... 1G-10
Pistons, Piston Rings, Connecting Rods, Fuel Pressure Inspection ................................. 1G-10
Cylinder and Crankshaft Components ............1D-41 Fuel System Diagnosis .................................... 1G-12
Pistons, Piston Rings, Connecting Rods, Fuel Injection System Troubleshooting ............ 1G-13
Cylinder and Crankshaft Disassembly and
Service Instructions .......................................... 1G-15
Assembly ........................................................1D-42
Fuel Pressure Relief Procedure ....................... 1G-15
Cylinder, Piston and Piston Ring Inspection
Fuel Line Removal and Installation .................. 1G-15
and Servicing ..................................................1D-49
Fuel Line Inspection ......................................... 1G-15
Piston Pin and Conrod Inspection.....................1D-52
Fuel Leakage Check Procedure....................... 1G-15
Crank Pin and Conrod Inspection .....................1D-53
Inspection of Fuel Hose Connections .............. 1G-16
Crankshaft Inspection .......................................1D-55
Fuel Vapor Separator Removal and
Crankshaft Main Bearing Inspection .................1D-56
Installation ...................................................... 1G-16
Crankshaft Oil Seal Inspection..........................1D-57
Fuel Vapor Separator Inspection ..................... 1G-17
High Pressure Fuel Pump Removal and
Power Unit Lubrication ............................1E-1
Installation ...................................................... 1G-18
General Description ............................................. 1E-1 High Pressure Fuel Pump Inspection............... 1G-18
Engine Lubrication Description ........................... 1E-1 Fuel Injector Inspection with Injector in
Schematic and Routing Diagram........................ 1E-1 Place .............................................................. 1G-19
Engine Oil Lubrication Chart ............................... 1E-1 Individual Fuel Injector Operating Sound
Diagnostic Information and Procedures............ 1E-2 Inspection....................................................... 1G-19
Oil Pressure Check ............................................. 1E-2 Fuel Injector Operating Signal Inspection ........ 1G-20
Low Oil Pressure Caution System ...................... 1E-2 Fuel Injector Removal and Installation ............. 1G-21
Powerhead Lubrication System Diagnosis.......... 1E-2 Low Pressure Fuel Pump Removal and
Service Instructions............................................. 1E-2 Installation ...................................................... 1G-23
Oil Pump Removal and Installation ..................... 1E-2 Low Pressure Fuel Pump Inspection ............... 1G-24
Oil Pump Disassembly and Assembly ................ 1E-3 In-line Fuel Filter Removal and Installation ...... 1G-24
Inspection Oil Pump Component Parts ............... 1E-4 Fuel Tank Construction .................................... 1G-25
Oil Pressure Switch Removal and Installation .... 1E-5 Fuel Tank Disassembly and Reassembly ........ 1G-26
Oil Pressure Switch Inspection ........................... 1E-6 Fuel Tank Components Inspection .................. 1G-26
Oil Strainer Removal and Installation.................. 1E-6
Oil Strainer Related Parts Inspection .................. 1E-6 Ignition System........................................ 1H-1
General Description .............................................1H-1
Power Unit Cooling System ....................1F-1 Ignition System Description.................................1H-1
General Description ............................................. 1F-1 Ignition Control Description .................................1H-2
Water Cooling System Description ..................... 1F-1 Component Location ...........................................1H-3
Displacement Type Water Pump Description ..... 1F-1 Ignition System Components Location................1H-3
Schematic and Routing Diagram........................ 1F-2 Diagnostic Information and Procedures ............1H-3
Cooling Water Circulation Chart.......................... 1F-2 Ignition System Symptom Diagnosis...................1H-3
Diagnostic Information and Procedures............ 1F-3 Ignition System Troubleshooting .........................1H-4
Powerhead Cooling System Diagnosis ............... 1F-3 Service Instructions .............................................1H-5
Service Instructions............................................. 1F-3 Spark Plug Removal and Installation ..................1H-5
Thermostat Removal and Installation.................. 1F-3 Spark Plug Inspection .........................................1H-5
Thermostat and Related Items Inspection .......... 1F-4 Ignition Coil Removal and Installation .................1H-5
Water Pump Removal and Installation................ 1F-5 Ignition Coil Inspection ........................................1H-6
Water Pump Related Item Inspection ................. 1F-5 Spark Plug Cap Inspection..................................1H-7
Water Tube Removal and Installation ................. 1F-5 Ignition Coil Primary Peak Voltage Inspection ....1H-7
 Table of Contents 1-iii

CKP Sensor Inspection .......................................1H-7 General Description ............................................. 1J-1

ECM Power Source Coil Inspection ....................1H-7 Manual Starting System ...................................... 1J-1
Emergency and Engine Stop Switch Service Instructions ............................................. 1J-2
Inspection..........................................................1H-7 Recoil Starter Components ................................. 1J-2
Recoil Starter Removal and Installation .............. 1J-3
Starting System .........................................1I-1 Recoil Starter Disassembly and Assembly ......... 1J-4
General Description .............................................. 1I-1 Recoil Starter Components Cleaning and
Electric Starter System Description...................... 1I-1 Inspection.......................................................... 1J-7
Start-In-Gear Protection System Description ....... 1I-2 NSI Cable Installation and Adjustment................ 1J-8
Component Location ............................................ 1I-3
Starting System Components Location................ 1I-3 Charging System ..................................... 1K-1
Diagnostic Information and Procedures............. 1I-3 General Description .............................................1K-1
Starter System Symptom Diagnosis .................... 1I-3 Charging System Description..............................1K-1
Starter System Troubleshooting .......................... 1I-4 Battery Requirement Description ........................1K-1
Service Instructions.............................................. 1I-8 Component Location ...........................................1K-2
Starter Motor Removal and Installation................ 1I-8 Charging System Components Location.............1K-2
Starter Motor Components................................... 1I-9 Diagnostic Information and Procedures ............1K-2
Starter Motor Disassembly and Assembly ......... 1I-10 Charging System Diagnosis................................1K-2
Starter Motor Components Inspection and Service Instructions .............................................1K-3
Servicing .......................................................... 1I-12 Charging System Construction ...........................1K-3
Starter Motor Relay Inspection .......................... 1I-14 Flywheel Removal and Installation......................1K-4
Neutral Switch Removal and Installation............ 1I-15 Battery Charge Coil Removal and Installation ....1K-5
Neutral Switch Inspection .................................. 1I-17 Battery Charge Coil Inspection ...........................1K-6
Starter Button Inspection ................................... 1I-18 ECM Power Source Coil Inspection ....................1K-7
Ignition Switch Inspection .................................. 1I-18 Rectifier / Regulator Removal and Installation ....1K-7
Rectifier / Regulator Inspection ...........................1K-9
Manual Starting System...........................1J-1 Fuse Inspection.................................................1K-10
Precautions........................................................... 1J-1
Precaution for Manual Starting System................1J-1
1-1 Precautions:

Precautions
Power Head

Precautions
Precautions for Powerhead
CENFL3121000001
Refer to “General Precautions” in Section 00 (Page 00-1).

NOTICE
If the electrical circuits is shorted while servicing the power head, the powerhead electrical circuit
could be damage seriously.

When the intended service operation does not require electric power supply from the battery, be sure
to disconnect the negative cable at the battery before starting the service work.
 Engine Control: 1A-1

Engine Control
Power Head

Precautions
Precautions on Engine Control Diagnosis
CENFL3121100001
! WARNING
Service operation of any type performed on engine control system involves a risk of fire and personal
injury if proper precaution are not taken.
To prevent any unexpected engine starting, perform the following before proceeding with any
CRANKING tests.
• When performing tests not related to fuel injector operation:
– Disconnect all fuel injector wire connectors.
• When performing tests related to fuel injector operation:
– Relieve the fuel pressure in the fuel lines. Refer to “Fuel Pressure Relief Procedure” in Section 1G
(Page 1G-15).
– Disconnect the high pressure fuel pump wire connector located on the high pressure fuel pump.

! CAUTION
If you do not disconnect the battery before disconnecting or connecting the wiring harness, you could
get an electrical shock.
• Always turn the ignition switch “OFF” and disconnect the battery cables when wires are being
disconnected or connected.

NOTICE
Failure to take proper precaution when disconnecting the harness connector can cause damage to the
wiring harness.

Hold and pull the connectors when disconnecting.

Do not pull the wires.

NOTE
• To troubleshoot the ECM, and the engine control system, consisting of sensors and actuators, use
the Suzuki Diagnostic System.
• The self-diagnostic codes memory in the ECM will remain even if the battery is disconnected.
• Each electrical circuit is affected by battery voltage, always use a full-charged battery.
• Make sure all ground points have good electrical contact.
• Make sure all wires / cables are securely connected.
1A-2 Engine Control:

General Description
Engine Control System Description
CENFL3121101001
The DF25A/30A models employ an integrated system which performs the control functions for fuel injection, ignition,
idle / trolling speed (idle air), etc. through the ECM (Engine Control Module).

System Structure

INPUT CONTROL OUTPUT

(sensor/switch) (ECM) (actuator etc.)

CKP sensor Fuel injection system Fuel injector

Ignition system Ignition coil

CMP sensor
Idle air control system IAC valve
MAP sensor
Fuel pump system High pressure fuel pump

Throttle position sensor

IAT sensor Caution system Caution lamp

Cylinder temp. sensor Self diagnostic system

Neutral switch Fail safe system

Oil pressure switch Operating hour indication system

Emergency stop switch Oil changing reminder system

Start-in-gear protection system

Tachometer
IFL311110001-02

NOTE
The engine operating time can be checked by SDS program Ver.7.00 and data base Ver.7.10.
 Engine Control: 1A-3

Engine Control System Flow Diagram

Electric starter model

26

27 28

21 35
30
2
31
1
19
18
32 9
5 34 8
33 7
17

36
6 29
16 13
37

23
14 3
22
20
15 4
24
25
12 10
11 10
IFL311110002-06

1. Flywheel 14. Battery charge coil 27. Fuel primer bulb

2. CKP sensor 15. Rectifier/regulator #2 28. Low pressure fuel filter
3. ECM power source coil 16. Starter button 29. Low pressure fuel pump
4. Rectifier/regulator #1 17. Starter relay 30. Fuel vapor separator
5. ECM 18. Neutral switch 31. Float
6. Cylinder temp. sensor 19. Fuse (30 A) 32. Fuel cooler
7. Spark plug 20. Emergency stop switch 33. In-line fuel filter
8. Ignition coil 21. Battery 34. High pressure fuel pump
9. CMP sensor 22. Fuel injector 35. Evaporation hose
10. MAP sensor 23. Air intake silencer case 36. Oil pressure switch
11. Throttle position sensor 24. Throttle body 37. By-pass air screw
12. IAT sensor 25. Intake manifold
13. IAC valve 26. Fuel tank
1A-4 Engine Control:

Manual starter model

21

22 23

30
25
2
26
1

27 9
5 29 8
4 28 7

14
6 24
15
13
31

18
3
17
16
19
20
12 10
11 10
IFL311110003-05

1. Flywheel 9. CMP sensor 17. Fuel injector 25. Fuel vapor separator
2. CKP sensor 10. MAP sensor 18. Air intake silencer case 26. Float
3. ECM power source coil 11. Throttle position sensor 19. Throttle body 27. Fuel cooler
4. Rectifier/regulator #1 12. IAT sensor 20. Intake manifold 28. In-line fuel filter
5. ECM 13. IAC valve 21. Fuel tank 29. High pressure fuel pump
6. Cylinder temp. sensor 14. Oil pressure switch 22. Fuel primer bulb 30. Evaporation hose
7. Spark plug 15. Neutral switch 23. Low pressure fuel filter 31. By-pass air screw
8. Ignition coil 16. Emergency stop switch 24. Low pressure fuel pump
 Engine Control: 1A-5

Engine Control Module (ECM)

CENFL3121101002
The ECM sends signals to control the actuators based on the information inputs from each sensor / switch.
Major controls are as follows:
Name of control Description
Fuel injection control • Controls fuel injection amount and timing.
Ignition control • Controls ignition timing.
• Controls idling / trolling speed by adjusting the intake air
Idle air control
volume through the IAC valve.
Fuel pump control • Controls the high pressure fuel pump drive.
• Informs the operator of abnormal engine conditions.
Caution system control
• Controls engine speed, if activated.
Self-diagnostic system control • Informs the operator of sensor / switch malfunction.
• Allows engine operation with a back-up system during sensor /
Fail-safe system control
switch malfunction.
Total operating hour indication system control —
• Informs the operator that it is time to replace the engine oil,
Oil changing reminder system control
based on the maintenance schedule.
• Prevents engine starting when the shift lever is positioned in
Start-in-gear protection system control
forward or reverse.

NOTE
• Information related to the Caution system, Self-Diagnostic System, and Total Operating Hours
System is retained in the ECM memory.
• The SDS program Ver.7.00 and data base Ver.7.10 are necessary for checking the total operating
time.
• ECM is different for DF25A and DF30A.

IFL311110033-01

1. ECM
1A-6 Engine Control:

ECM Input / Output Circuit Diagram

Tiller handle model

ECM POWER
SOURCE COIL
RECTIFIER/ RECTIFIER/
REGULATOR No.2 REGULATOR No.1

5 DC POWER
BATTERY
CHARGE COIL
POWER OUTPUT 7

FUEL INJECTOR #1 32
19 CKP SENSOR

FUEL INJECTOR #2 33
2 CMP SENSOR
10 POWER FOR SENSOR FUEL INJECTOR #3 34

21 TPS

6 MAP SENSOR
IAC VALVE 31
30 A

HIGH PRESSURE FUEL PUMP (U) 14 HIGH

BATTERY PRESSURE
HIGH PRESSURE FUEL PUMP (V) 13 FUEL
HIGH PRESSURE FUEL PUMP (W) 12 PUMP

4 IAT SENSOR BUZZER 27 BZ

START
SWITCH
DIAG LED 11
20 CYLINDER TEMP. SENSOR

STARTER RELAY
OIL PRESSURE LED 29
3 ECM GND

OVER HEAT LED 30

NEUTRAL
SWITCH

24 OIL PRESSURE SWITCH

TACHOMETER 26
25 NEUTRAL SWITCH

IGNITION COIL #1 17
22 EMERGENCY STOP SWITCH

IGNITION COIL #2 16

IGNITION COIL #3 15

COMMUNICATION LINE A 8
SDS TOOL

POWER GND 9

IFL311110005-10

• Manual starter model: Only the solid line

• Electric starter model: Both the solid line and the dotted line
 Engine Control: 1A-7

Remote control model

ECM POWER
SOURCE COIL
RECTIFIER/ RECTIFIER/
REGULATOR No.2 REGULATOR No.1

5 DC POWER
BATTERY
CHARGE COIL
POWER OUTPUT 7

FUEL INJECTOR #1 32
19 CKP SENSOR

FUEL INJECTOR #2 33
2 CMP SENSOR
10 POWER FOR SENSOR FUEL INJECTOR #3 34

21 TPS

6 MAP SENSOR
IAC VALVE 31

IGNITION SWITCH HIGH PRESSURE FUEL PUMP (U) 14 HIGH

PRESSURE
S.T. OFF HIGH PRESSURE FUEL PUMP (V) 13 FUEL
HIGH PRESSURE FUEL PUMP (W) 12 PUMP

10 A BUZZER 27 BZ
4 IAT SENSOR

DIAG LED 11
20 CYLINDER TEMP. SENSOR

30 A STARTER RELAY OIL PRESSURE LED 29

3 ECM GND

OVER HEAT LED 30

BATTERY NEUTRAL
SWITCH

OVER REV LED 28

24 OIL PRESSURE SWITCH

TACHOMETER 26
25 NEUTRAL SWITCH

IGNITION COIL #1 17
22 EMERGENCY STOP SWITCH

IGNITION COIL #2 16

IGNITION COIL #3 15

COMMUNICATION LINE A 8
SDS TOOL

POWER GND 9

IFL311110004-12
1A-8 Engine Control:

ECM Connector / Terminal Layout

“A”

IFL311110006-04

“A”: ECM

Terminal Wire color Circuit

1 — —
2 Y/Bl CMP sensor
3 B Ground for ECM
4 Lg/R IAT sensor
5 R/Y DC power for ECM
6 W MAP sensor
7 Gr Power output
8 Y/R Communication line A
9 B Ground for power
10 R Power for sensor
11 G/W Diagnosis LED
12 B/R High pressure fuel pump (W)
13 B/Y High pressure fuel pump (V)
14 B/W High pressure fuel pump (U)
15 Bl/Y Ignition coil #3
16 Bl Ignition coil #2
17 O Ignition coil #1
18 — —
19 R/B CKP sensor
20 B/O Cylinder temp. sensor
21 Br/Bl Throttle position sensor
22 Bl/O Emergency stop switch
23 — —
24 Bl/Y Oil pressure switch
25 G Neutral switch
26 Y/B Tachometer
27 Bl/W Buzzer
28 P/G Over revolution LED
29 Bl/B Oil pressure LED
30 G/Y Over heat LED
31 W/B IAC valve
32 O/B Fuel injector #1
33 B/Br Fuel injector #2
34 R/W Fuel injector #3

• Wire color of No.25 terminal for the manual starter models is Y/W.
• Terminal No.28 is applicable to the remote control models only.
 Engine Control: 1A-9

Caution System Description

CENFL3121101003
The following three caution systems alert the operator when an abnormality occurs on the engine.
• OVER-REVOLUTION CAUTION
• LOW OIL PRESSURE CAUTION
• OVERHEAT CAUTION
Front panel / Monitor-Tachometer

“A” “B” “C”

“G”
“D”

“E” “F”
IFL311110030-03

“A”: “TEMP” lamp “C”: “CHECK ENGINE” lamp “E”: “TEMP” lamp “G”: “REV-LIMIT” lamp
“B”: “OIL” lamp “D”: “CHECK ENGINE” lamp “F”: “OIL” lamp

Caution type Caution lamp *Caution buzzer Engine RPM limited

Over-revolution No Yes Yes
Low oil pressure Yes on “B” Yes Yes
Overheat Yes on “A” Yes Yes

*: Remote control model

Caution lamp
Caution type
(Monitor-Tachometer)
Over-revolution Yes on “G”
Low oil pressure Yes on “F”
Overheat Yes on “E”

Lamp Check
1) Three caution lamps located on front panel:
For two seconds after inputting electric power to the ECM:
• Three caution lamps turns ON.
2) Four caution lamps located on Monitor-tachometer:
When the ignition key is turned to the “ON” position:
• Four caution lamps turns ON for two seconds.

Buzzer Check
When the ignition key is turned to the “ON” position:
• Caution buzzer sounds for two seconds.
1A-10 Engine Control:

Over-Revolution Caution System

Condition:
The ECM controlled over revolution limiter will engage at the engine speeds shown below. Once engaged it will initiate
an intermittent fuel injection signal to reduce engine speed.
Over revolution limiter
DF25A: 6 200 r/min
DF30A: 6 400 r/min

Action:
Engine speed • Automatically reduced to approx. 3 000 r/min. by an intermittent fuel injection
signal.
• If the operator decreases the engine speed below the over revolution system
maximum preset value, within 10 seconds, the over-revolution caution control
will be cancelled.
Caution lamp (front panel) Lamp does not light.
Caution lamp (Monitor-tachometer) “REV-LIMIT” lamp lights continuously.
Caution buzzer Sounds in a series of long (1.5 sec.) beeps.

Reset:
Close the throttle to reduce the engine speed below approx. 3 000 r/min. for four seconds.

NOTE
In neutral gear, the preset maximum engine speed value before the over-revolution caution system
activates is 3 000 r/min.
In the operation of Neutral gear over-revolution caution system, the caution lamp does not light.
To cancel the Neutral gear over-revolution caution control, close throttle completely.
 Engine Control: 1A-11

Low Oil Pressure Caution System

Condition:
Immediate activation of the system when the oil pressure switch is turned “ON” due to an engine oil pressure drop
below 30 kPa (0.3 kg/cm2, 4.3 psi) while engine is running.

Action:
Engine speed • Automatically reduced to approx. 1 000 r/min. maximum by an intermittent fuel
injection signal.
• The engine automatically stops 3 minutes after the caution system is activated.
Caution lamp (front panel) “OIL” lamp lights continuously.
Caution lamp (Monitor-tachometer) “OIL” lamp lights continuously.
Caution buzzer Sounds in a series of long (1.5 sec.) beeps.

NOTE
If the engine is automatically stopped due to the caution system, the engine can be started again.
However, the caution system will repeatedly activate until the cause is eliminated.

Reset:
Stop the engine and check the engine oil level. Refill the engine oil to the correct level if it is below the low oil level
mark.
If the engine oil level is correct, the following causes may be considered:
• Improper oil viscosity.
• Malfunctioning oil pressure switch.
• Clogged oil strainer or oil filter.
• Worn oil pump relief valve.
• Oil leakage from the oil passage.
• Excessive wear / damage of oil pump.

NOTE
The low oil pressure caution system will reset when the oil pressure is restored to over 30 kPa (0.3 kg/
cm2, 4.3 psi) at approx. 1 000 r/min. or less engine speed operation.
The engine must be stopped and checked immediately once the system is activated.

Overheat Caution System

Immediate activation of the system when:
• Cylinder temperature reaches 100 °C (212 °F)
• The rate of cylinder wall temperature variation within a given time exceeds the preset rate.

Action:
Engine speed • Automatically reduced to approx. 3 000 r/min. maximum by intermittent fuel
injection and ignition signals.
• The engine automatically stops 3 minutes after the caution system is activated.
Caution lamp (front panel) “TEMP” lamp lights continuously.
Caution lamp (Monitor-tachometer) “TEMP” lamp lights continuously.
Caution buzzer Sounds in a series of long (1.5 sec.) beeps.

NOTE
If the engine is automatically stopped due to the caution system, the engine can be started again.
The caution system will repeatedly activate until the cause is eliminated.

Reset:
System reset will occur when the cylinder temperature drops below the limits shown below. However, the system may
be activated again unless the cause for overheat (such as insufficient water) is removed.
Reset temperature Approx. 78 °C (172 °F)
1A-12 Engine Control:

Self-Diagnostic System Description

CENFL3121101004
The self-diagnostic system alerts the operator when an abnormality occurs in a signal from a sensor, or switch, etc.
When the system is activated, the “CHECK ENGINE” lamp flashes (lights intermittently) according to each code
pattern.

NOTE
On the remote control model;
• The buzzer sound will be stopped approx. 30 seconds after activating the diagnostic system during
engine operation.
• Diagnostic code indication appears by the “CHECK ENGINE” lamp during ignition key turns ON.
However, the buzzer does not sound when engine stops.

Front panel / Monitor-Tachometer

“A”

“A”
IFL311110032-02

“A”: “CHECK ENGINE” lamp

Priority / Code / Pattern for Self-Diagnostic System Operation

0: OFF, 1: ON
Priority Failed item Code Lamp flashing pattern Fail-Safe system active
1

1 MAP sensor 1 3–4 0

Yes
MCODE00D34-0-01
1

2 Cylinder temp. sensor 1–4 0

Yes
MCODE00D14-0-01
1

3 IAT sensor 2–3 0

Yes
MCODE00D23-0-01
1

4 CKP sensor 4–2 0

No
MCODE00D42-0-01
1

5 CMP sensor 2–4 0

No
MCODE00D24-0-01
1

6 Air intake system 2–2 0

Yes
MCODE00D22-0-01
1

7 MAP sensor 2 3–2 0

No
MCODE00D32-0-01
1

8 Fuel injector 4–3 0

No
MCODE00D43-0-01
1

9 Throttle position sensor 2–1 0

Yes
MCODE00D21-0-01
1
Rectifier / Regulator
10 1–1 No
(Over-charging) 0
MCODE00D11-0-01
1
Oil pressure switch
11 5–3 No
(Remote control model) 0
MCODE00D53-0-01
 Engine Control: 1A-13

NOTE
• If two or more items fail at once, the self-diagnostic indication appears according to the priority
order. The indication repeats three times.
• If the failed item remains, the self-diagnostic indication appears again after starting the engine.
• After correcting the failed item, the self-diagnostic indication appears until the ECM receives the
proper signal with the engine running.
• Cancellation of the self-diagnostic indication is automatically performed when the failure is
corrected and a normal signal is received by the ECM for a period of 20 – 30 seconds.

NOTE
Monitoring of rectifier/regulator output;
• On tiller handle model, the ECM power line of rectifier/regulator is only monitored, but not the
battery charge line.
• On remote control model, both the battery charge line and ECM power line of rectifier/regulator are
monitored.

Condition for Self-Diagnostic System Operation

Failed item Condition
• No signal (With engine running).
MAP sensor 1 • Receiving an out of range “37 – 860 mmHg (1.45 – 33.85 inHg) (0.2 – 4.5
V)” signal (With the engine running.).
• No signal.
Cylinder temp. sensor • Receiving an out of range “– 40 to + 200 °C (– 40 to +392 °F) (0.10 – 4.9
V)” signal.
• No signal.
IAT sensor • Receiving an out of range “– 40 to + 170 °C (– 40 to +338 °F) (0.10 – 4.8
V)” signal.
• During the rotation of the predetermined crankshaft angle, the normal CKP
CKP sensor
sensor signal pattern is not received by the ECM.
• During eight crankshaft rotation, the normal CMP sensor signal pattern is
CMP sensor
not received by the ECM.
• The engine operates at an abnormally high speed when the ECM is
Air intake system receiving a completely closed signal from the throttle position sensor.
(Criterion: 2 100 r/min minimum)
• From throttle position sensor, the full close signal is inputted, but from the
MAP sensor 2
MAP sensor, the signal voltage exceeds 2.4 V.
Fuel injector • No operation signal from the ECM.
• No signal.
Throttle position sensor
• Receiving an out of range “0.2 – 4.8 V” signal.
Rectifier / Regulator • Receiving 16 volts or higher signal.
(Over-charging)
Oil pressure switch • While the engine is stopped and the ignition switch is on, the ECM receives
(Remote control model) an “off” signal from the oil pressure switch.
1A-14 Engine Control:

Fail-Safe System Description

CENFL3121101005
The fail-safe system is closely related to the self-diagnostic system.
When an abnormality occurs in a sensor signal, the ECM ignores the out-of-range signal and assumes a pre-
programmed value for the failed sensors.
This allows the engine to continue running under the fail-safe condition.

Pre-Programmed Value for Fail-Safe System

Failed item Pre-Programmed value
MAP sensor 1 • 150 – 758 mmHg (5.9 – 30 inHg.)
(The value will change according to the current engine speed.)
• The control is executed with the maximum engine speed of 4 000 r/min.
Air intake system • The control is executed with the maximum engine speed of 2 000 r/min.
Cylinder temp. sensor 60 °C (140 °F)
IAT sensor 45 °C (113 °F)
Throttle position sensor • The control is executed with the throttle opening at 30 degrees.

NOTE
There is no back-up system for the ECM itself. The engine will stop if it has failed.

Oil Change Reminder System Description Indication of System Activation

CENFL3121101006
This system informs the operator that it is time to change
the ENGINE OIL based on the recommended Caution lamp flashing pattern
maintenance schedule. 0.3 sec
When the total motor operating hours has reached the
pre-programmed hours, the “OIL” lamp will flash while
the engine is running or the ignition switch is ON.
The above mentioned indication will repeat until the
activated system is manually canceled. 0.3 sec

IFL311110039-01
NOTE
On the remote control model; Action
When the oil change reminder system is
activated, the buzzer will begin a series of Starting operation
double beeps after starting engine. This (*1) (*4)
function is added to “OIL lamp flashing”.
Indication Cancellation
The buzzer sound will be stopped approx. 30
seconds after engine is started. (*2) (*4)

Indication Cancellation
NOTE
(*3) (*4)
This system will activate up to 2 100 hour’s
operation. Indication Cancellation
(*3) (*4)

Indication Cancellation
1

Repeat
I9J011110010-03

*1: Lapse of initial 20 hour’s operation

*2: Lapse of 80 hour’s operation
*3: Lapse of 100 hour’s operation
*4: When performing cancellation before system activation
IFL311110031-03

1. “OIL” lamp
 Engine Control: 1A-15

Cancellation Procedure Remote control model

Tiller handle model 1) Turn the ignition key to the “ON” position.
1) Start the engine. 2) Remove the emergency stop switch plate (1).
Make sure that shift is in neutral and close the 3) Pull out the emergency stop switch knob (2) three
throttle fully. times in three seconds.
NOTE A short beep will be heard if the cancellation is
successful.
The engine stops when the engine stop
button is kept to push than 0.5 seconds. 4) Turn the ignition key to the “OFF” position.
5) Set the emergency stop switch plate (1) into the
2) Push the engine stop button (1) three times within original position.
three seconds so that engine should not stall.
The caution lamp is no longer lit when the reminder
cancellation is successful.
3) Stop the engine.
1

I9J011110007-02
1
NOTE
IDK111110026-01
• Cancellation of the system is possible
whether or not the engine oil has been
replaced.
Once the system has been activated,
SUZUKI strongly recommends that the
engine oil be replaced before canceling the
system.
• If the engine oil has been replaced with the
system not activated, it is still necessary to
perform the cancellation procedure to
reset the Oil Change Reminder System.
1A-16 Engine Control:

Component Location
Engine Control System Components / Engine Electrical Device Location
CENFL3121103001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-7).

Diagnostic Information and Procedures

Troubleshooting with Self-Diagnostic Code
CENFL3121104001
! WARNING
Before troubleshooting, read and follow the “Precautions on Engine Control Diagnosis” (Page 1A-1).

In this section, troubleshooting procedures are based on the assumption that the “Low pressure fuel system” and
“mechanical components (power unit, lower unit, etc.)” are normal.

Self-Diagnostic Code “3 – 4” MAP Sensor

CENFL3121104002
Wiring Diagram

ECM
1
5V
4
W
C 3
P
B U
5V 2
R

IFL311110007-01

1. MAP sensor 3. ECM power source cable (Tiller handle model only)
2. 12 V battery (Tiller handle model only) 4. SDS communication connector

Troubleshooting Is it in good condition?

Step 1 Yes Substitute a good ECM and recheck.

1) Stop the engine. No • Faulty MAP sensor.
2) Disconnect the MAP sensor connector. • “R” wire shorted to “W” wire, “B” wire
3) On the tiller handle model; connect the ECM open, poor “B” wire connection, poor
power source cable to the SDS communication “W” wire connection, “W” wire open or
connector and battery. poor MAP sensor connection.
4) On the remote control model; turn the ignition • If the wiring and connection is OK,
switch ON. intermittent trouble or a faulty ECM may
5) Check the voltage at the “R” wire terminal of the be the cause.
MAP sensor connector.
Is the voltage approx. 4 – 5 V? For step 1
Yes Go to step 2.

No • “R” wire open, “R” wire shorted to

ground or a poor wire connection.
• If the wiring and connection is OK,
substitute a known-good ECM and
recheck.

Step 2
1) Check the MAP sensor output voltage change.
Refer to “MAP Sensor Output Voltage Inspection”
IDK111110033-01
in Section 1C (Page 1C-11).
 Engine Control: 1A-17

Self-Diagnostic Code “1 – 4” Cylinder Temp. Sensor

CENFL3121104003
Wiring Diagram

ECM

1 B B/O C 4
P 2
B B U
3

IFL311110008-01

1. Cylinder temp. sensor 3. 12 V battery (Tiller handle model only)

2. ECM power source cable (Tiller handle model only) 4. SDS communication connector

Troubleshooting

Step 1
1) Stop the engine.
2) Disconnect the cylinder temp. sensor connector.
3) On the tiller handle model; connect the ECM power source cable to the SDS communication connector and
battery.
4) On the remote control model; turn the ignition switch ON.
5) Check the voltage at the “B/O” wire terminal of the cylinder temp. sensor connector.
Is the voltage 4 V or more?

Yes Go to step 2.

No • “B/O” wire shorted to the “B” wire or ground circuit.

• If the wiring is OK, substitute a known-good ECM and recheck.

Step 2
1) Disconnect the ECM power source cable.
2) Check the Cylinder temp. sensor.
Refer to “Cylinder Temp. Sensor Inspection” in Section 1C (Page 1C-9).
Is it in good condition?

Yes Poor cylinder temp. sensor connection, intermittent trouble or a faulty ECM may be the cause.

No Faulty cylinder temp. sensor.

For step 1

I9J011110045-02
1A-18 Engine Control:

Self-Diagnostic Code “2 – 3” IAT Sensor

CENFL3121104004
Wiring Diagram

ECM
5V
1 B Lg/R C 4
P 2
B B U
3

IFL311110009-01

1. IAT sensor 3. 12 V battery (Tiller handle model only)

2. ECM power source cable (Tiller handle model only) 4. SDS communication connector

Troubleshooting

Step 1
1) Stop the engine.
2) Disconnect IAT sensor connector.
3) On the tiller handle model; connect the ECM power source cable to the SDS communication connector and
battery.
4) On the remote control model; turn the ignition switch ON.
5) Check the voltage at the “Lg/R” wire terminal of the IAT sensor connector.
Is the voltage 4 V or more?

Yes Go to step 2.

No • “Lg/R” wire shorted to “B” wire or ground circuit.

• If the wiring is OK, substitute a known-good ECM and recheck.

Step 2
1) Disconnect the ECM power source cable.
2) Check the IAT sensor.
Refer to “IAT Sensor Inspection” in Section 1C (Page 1C-9).
Is it in good condition?

Yes Poor IAT sensor connection, intermittent trouble or a faulty ECM may be cause.

No Faulty IAT sensor.

For step 1

I9J011110046-01
 Engine Control: 1A-19

Self-Diagnostic Code “4 – 2” CKP Sensor

CENFL3121104005
Wiring Diagram

ECM

R/B R/B C
P
B/G B U

IFL311110010-01

1. CKP sensor

Troubleshooting

Step 1
1) Check the CKP sensor air gap.
Refer to “CKP Sensor Removal and Installation” in Section 1C (Page 1C-7).
Is it in good condition?

Yes Go to step 2.

No Incorrectly adjusted air gap.

Step 2
1) Check the CKP sensor resistance.
Refer to “Resistance Check” in Section 1C (Page 1C-5).
Is it in good condition?

Yes Open wire between the CKP sensor and the ECM, poor lead wire connection or sensor lead wires are
shorted to each other. If lead wire and connection are OK, intermittent trouble or a faulty ECM may be
the cause.

No Faulty CKP sensor.

1A-20 Engine Control:

Self-Diagnostic Code “2 – 4” CMP Sensor

CENFL3121104006
Wiring Diagram

1
ECM
Gr
Y/Bl
C 4
P 2
B U
3

IFL311110011-03

1. CMP sensor 3. 12 V battery (Tiller handle model only)

2. ECM power source cable (Tiller handle model only) 4. SDS communication connector

Troubleshooting Step 4
Step 1 Was terminal “Gr” voltage in step 2 within
specification?
Is CMP sensor installed properly and the wire
harness connected securely? Yes Go to step 5.
Yes Go to step 2. No “Gr” wire open circuit. If the wiring and
connection is OK, substitute a known-
No Correct.
good ECM and recheck.
Step 2
Step 5
1) Stop the engine.
1) Disconnect the ECM power source cable. (Tiller
2) Disconnect the connector from the CMP sensor. handle model)
3) On the tiller handle model; connect the ECM 2) Check the CMP sensor and sensor trigger vane.
power source cable to the SDS communication Refer to “CMP Sensor Inspection” in Section 1C
connector and battery. (Page 1C-10).
4) On the remote control model; turn the ignition
Is check result satisfactory?
switch ON.
5) Check for proper connection to the CMP sensor at Yes Substitute a known-good ECM and
“Gr”, “Y/Bl” and “B” wire terminals. recheck.
6) If OK, check the voltage at the “Gr”, “Y/Bl” and “B” No Replace CMP sensor.
wire terminals of the CMP sensor connector.
CMP sensor voltage
Terminal “Gr”: 10 – 14 V For step 2
Terminal “Y/Bl”: 4 – 5 V
Terminal “B”: 0 V
Is the voltage satisfactory? B
Yes Go to step 5. Y/Bl

No Go to step 3. Gr
IFL311110012-02

Step 3
Was terminal “Y/Bl” voltage in step 2 within
specification?

Yes Go to step 4.

No “Y/Bl” wire open or shorted to ground /

power supply circuit. If the wiring and
connection is OK, substitute a known-
good ECM and recheck.
 Engine Control: 1A-21

Self-Diagnostic Code “2 – 2” Air Intake System

CENFL3121104007
Wiring Diagram

1 ECM
5V
4
R
3
Br/Bl
C
P 2
B U

IFL311110013-01

1. TPS 3. ECM power source cable (Tiller handle model only)

2. 12 V battery (Tiller handle model only) 4. SDS communication connector

Troubleshooting Step 3
Step 1 1) Check the MAP sensor, IAC system and intake
manifold (system) for air leakage.
1) Stop the engine.
2) Disconnect the TPS connector. Is the result OK?
3) On the tiller handle model; connect the ECM Yes Intermittent trouble or faulty ECM.
power source cable to the SDS communication Substitute a known-good ECM and
connector and battery. recheck.
4) On the remote control model; turn the ignition
No Faulty air intake system.
switch ON.
5) Check the voltage at the “R” wire terminal of TPS
connector. For step 1
Is the voltage approx. 4 – 5 V?

Yes Go to step 2.

No • “R” wire open, “R” wire shorted to R

ground circuit or poor wire connection.
• If the wiring and connection is OK,
substitute a known-good ECM and
recheck. B
Br/Bl

Step 2
1) Check the TPS output voltage change. IFL311110014-01
Refer to “TPS Inspection” in Section 1C (Page 1C-
14).
Is it in good condition?

Yes Go to step 3.

No • Faulty TPS.
• “R” wire shorted to “Br/Bl” wire, “B” wire
open, poor “B” wire connection, poor
“Br/Bl” wire connection, “Br/Bl” wire
open or poor TPS connection.
• If the wiring and connection is OK,
intermittent trouble or a faulty ECM may
be the cause.
1A-22 Engine Control:

Self-Diagnostic Code “3 – 2” MAP Sensor 2

CENFL3121104008
Wiring Diagram

ECM
1 +5V
R 5V
Br/Bl

B
C 5
4
P
U 3
2 W
B
5V
R

IFL311110015-01

1. TPS 4. ECM power source cable (Tiller handle model only)

2. MAP sensor 5. SDS communication connector
3. 12 V battery (Tiller handle model only)

Troubleshooting

Step 1
1) Stop the engine.
2) Disconnect the MAP sensor connector.
3) On the tiller handle model; connect the ECM power source cable to the SDS communication connector and
battery.
4) On the remote control model; turn the ignition switch ON.
5) Check the voltage at the “R” wire terminal of the MAP sensor connector.
Is the voltage approx. 4 – 5 V?

Yes Go to step 2.

No • “R” wire open, “R” wire shorted to ground circuit or poor wire connection.
• If the wiring and connection is OK, substitute a known-good ECM and recheck.

Step 2
1) Check the MAP sensor output voltage change.
Refer to “MAP Sensor Output Voltage Inspection” in Section 1C (Page 1C-11).
Is it in good condition?

Yes Go to step 3.

No Faulty MAP sensor.

 Engine Control: 1A-23

Step 3
1) Disconnect the TPS connector.
2) Check the voltage at the “R” wire terminal of the TPS connector.
Is the voltage approx. 4 – 5 V?

Yes Go to step 4.

No • “R” wire open, “R” wire shorted to ground circuit or poor wire connection.
• If the wiring and connection is OK, substitute a known- good ECM and recheck.

Step 4
1) Check the TPS output voltage change.
Refer to “TPS Inspection” in Section 1C (Page 1C-14).
Is it in good condition?

Yes Intermittent trouble, substitute a known-good ECM and recheck.

No • Faulty TPS.
• “R” wire shorted to “Br/Bl” wire, “B” wire open, poor “B” wire connection, poor “Br/Bl” wire connection,
“Br/Bl” wire open or poor TPS connection.
• If the wiring and connection is OK, intermittent trouble or a faulty ECM may be the cause.

For step 1

B
W

IDK111110027-03
1A-24 Engine Control:

Self-Diagnostic Code “4 – 3” Fuel Injector

CENFL3121104009
Wiring Diagram

Gr

1 ECM
#1
O/B
#2 4
C 3
B/Br
#3 2
P
R/W
U

IFL311110016-01

1. Fuel injector 3. ECM power source cable (Tiller handle model only)
2. 12 V battery (Tiller handle model only) 4. SDS communication connector

Troubleshooting Is the voltage 12 V (battery voltage)?

Step 1 Yes Go to step 4.

1) On the remote control model; turn the ignition No Power circuit open.
switch “ON”.
2) Using a sound scope, check that each injector has Step 4
an operating sound when the engine is cranking. 1) Disconnect the ECM power source cable. (Tiller
Do all injectors make an operating sound? handle model)
2) Disconnect the ECM connector, and check all of
Yes Fuel injector and its circuit are in good the injectors for resistance.
condition. Refer to “Resistance Check” in Section 1C (Page
1C-5).
No Go to step 2.
Is the resistance 10 – 14 Ω for each injector?
Step 2
Yes Substitute a known-good ECM and
1) Check the fuel injector, the wiring connection and
recheck.
the wire harness of the fuel injector not making the
operating sound. No Faulty injector or its circuit.
Are all of the above OK?

Yes Substitute a known-good ECM and For step 3

recheck.

No Faulty injector or its circuit.

Step 3
1) Stop the engine.
Gr
2) Disconnect the connector from the fuel injector.
3) On the tiller handle model; connect the ECM
power source cable to the SDS communication IFL311110017-01
connector and battery.
4) On the remote control model; turn the ignition
switch ON.
5) Check the voltage at “Gr” wire terminal.
 Engine Control: 1A-25

Self-Diagnostic Code “2 – 1” TPS (Throttle Position Sensor)

CENFL3121104010
Wiring Diagram

1 ECM
5V
R 4
C 3
Br/Bl
P
B U 2

IFL311110018-01

1. TPS 3. ECM power source cable (Tiller handle model only)

2. 12 V battery (Tiller handle model only) 4. SDS communication connector

Troubleshooting

Step 1
1) Stop the engine.
2) Disconnect TPS connector.
3) On the tiller handle model; connect the ECM power source cable to the SDS communication connector and
battery.
4) On the remote control model; turn the ignition switch ON.
5) Check the voltage at the “R” wire terminal of the TPS connector.
Is the voltage approx. 4 – 5 V?

Yes Go to step 2.

No • “R” wire open, “R” wire shorted to ground circuit or poor connection.
• If the wiring and connection is OK, substitute a known-good ECM and recheck.

Step 2
1) Check the TPS output voltage change.
Refer to “TPS Inspection” in Section 1C (Page 1C-14).
Is it in good condition?

Yes Substitute a known-good ECM and recheck.

No • Faulty TPS.
• “R” wire shorted to “Br/Bl” wire, “B” wire open, poor “B” wire connection, poor “Br/Bl” wire connection,
“Br/Bl” wire open or poor TPS connection.
• If the wiring and connection is OK, intermittent trouble or a faulty ECM may be the cause.
1A-26 Engine Control:

Self-Diagnostic Code “1 – 1” Rectifier / Regulator (Over Charging)

CENFL3121104011
NOTE
• On the tiller handle model;
The diagnostic code for Rectifier/Regulator is displayed only when failure exists in rectifier/
regulator No.1 for ECM power.
• On the remote control model;
The diagnostic code for Rectifier/Regulator is displayed when failures exist in rectifier/ regulator
No.1 for ECM power and/ or rectifier/ regulator No.2 for battery charging.

NOTE
It is difficult to thoroughly check the rectifier / regulator. Before replacing it with new one, check that
the ground point has good electrical contact.

Troubleshooting

Step 1
1) Check the rectifier / regulator.
Refer to “Rectifier / Regulator Inspection” in Section 1K (Page 1K-9).
Is the result OK?

Yes Go to step 2.

No Faulty rectifier / regulator.

Step 2
1) With the engine running, check charging voltage at idle speed.
Is the result 16 V or higher?

Yes Faulty rectifier / regulator.

No Faulty ECM or wire continuity / connection failure.

 Engine Control: 1A-27

Self-Diagnostic Code “5 – 3” Oil Pressure Switch

CENFL3121104012
Wiring Diagram

ECM
1

C
Bl/Y
P
U

IFL311110029-01

1. Oil pressure switch

Troubleshooting

Step 1
1) Stop the engine.
2) Remove the oil pressure switch wire at switch.
3) With the ignition switch “ON”, check the voltage between the oil pressure switch wire terminal and body ground.
Is the voltage approx. 4 – 5 V?

Yes Go to step 2.

No • Oil pressure switch wire open or poor connection.

• If wire and connection are OK, substitute a known-good ECM and recheck.

Step 2
1) Check the oil pressure switch operation.
Refer to “Oil Pressure Switch Inspection” in Section 1E (Page 1E-6).
Is it in good condition?

Yes Poor oil pressure switch wire connection, intermittent trouble or a faulty ECM may be the cause.

No Faulty oil pressure switch.

For step 1

I9J011110064-01
1A-28 Engine Control:

Troubleshooting Without Self-Diagnostic Code

CENFL3121104013
Before troubleshooting, make sure that there is not a self-diagnostic code indication.

Condition Possible cause Correction / Reference Item

Unstable idling / trolling Clogged MAP sensor vacuum passage. Check the vacuum passage.
(or engine tends to stall) Malfunctioning TPS. Check the TPS sensor.
Faulty IAC system. Check the IAC system.
Fuel pressure out of specification. Check the fuel pressure.
Faulty injector or its circuit. Check the injector and its circuit.
Poor performance of the IAT sensor, Check each sensor.
TPS or MAP sensor.
Faulty ECM. Replace.
Faulty spark plug. Replace.
Faulty ignition coil or its circuit. Check the ignition coil and its circuit.

IAC System Troubleshooting

CENFL3121104014
Wiring Diagram

ECM
1

Gr

W/B

IFL311110019-01

1. IAC valve

Troubleshooting

Step 1
1) Warm up the engine to normal operating temperature and keep it idling.
2) Using the SDS tool, check the IAC duty cycle and idle speed. Adjust if necessary.
Idle speed (IAC duty cycle)
800 – 900 r/min (approx. 10%)
Is result OK?

Yes IAC system is in good condition.

No Go to step 2.

Step 2
1) Disconnect the IAC connector at IAC valve.
2) Check the resistance between terminals.
Is the resistance 22 – 26 Ω?

Yes Proceed to “Unstable Idling / Trolling” in “Troubleshooting Without Self-Diagnostic Code” (Page 1A-28)
and check items except for “Faulty IAC system”.

No • Faulty IAC valve.

• Poor connection.
• Open wire harness.
 Engine Control: 1A-29

Service Instructions
How to Use The 34 Pin Test Cord
CENFL3121106001
This test cord is used when checking a circuit for voltage, etc. and is connected between the ECM and the wiring
harness.
To take a measurement, connect the tester probe to the relevant terminal of the test cord.

NOTE
In this model, the 18 pin test cord in the test cord set is not required.

Special tool
(A): 09930–89290 (18 pin & 34 pin test cord)

(A)

3 4

1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
14 15 16 17 31 32 33 34

2
IFL311110020-01

1. ECM 2. Wire harness 3. White connector 4. Black connector

1A-30 Engine Control:

Inspection of The ECM and Its Circuit

CENFL3121106002
NOTICE
If you connect a voltmeter or ohmmeter directly to ECM terminals by removing ECM connector, you
can damage the control module.

Never connect a voltmeter or an ohmmeter directly to any terminal of ECM by disconnecting control
module connector.

Special tool
(A): 09930–89290 (18 pin & 34 pin test cord)
(B): 09933–08910 (ECM power source cable)
(C): 09900–25008 (Multi circuit tester set)
Tester knob indication
DCV
1) Stop the engine.
2) Connect the 34-pin test cord between the ECM and wire harness as shown in figure.

(A)

3
2

1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
14 15 16 17 31 32 33 34

(C)
IFL311110021-02

1. ECM 2. White connector 3. Black connector

3) On the tiller handle model; connect the ECM power source cable to the SDS communication connector (1) and 12
V battery as shown figure.

(B)

IFL311110034-01

4) On the remote control model; turn the ignition switch ON.

5) Connect the tester probe (“–”, Black) to body ground, and measure the voltage according to the “Circuit Voltage
Table” (Page 1A-31).
 Engine Control: 1A-31

Circuit Voltage Table

Tiller handle model

“A”

IFL311110006-04

“A”: ECM terminal

Wire
Terminal Circuit Standard voltage Condition / Remarks
color
1 — — — —
2 Y/Bl CMP sensor Approx. 0.3 V or 5 V 12 V electric power is supplied to ECM.
3 B Ground for ECM — —
4 Lg/R IAT sensor 0.04 – 4.6 V 12 V electric power is supplied to ECM.
• Disconnect ECM power source cable.
• Crank with recoil starter.
• Use peak reading volt meter CD-77
5 R/Y DC power for ECM Approx. 8 V or over • Tester knob indication: POS50
• Disconnect ECM power source cable.
• Crank with starter motor
• Use Multi circuit tester set.
6 W MAP sensor 0.79 – 4.2 V 12 V electric power is supplied to ECM.
• Disconnect ECM power source cable.
• Crank with recoil starter.
• Use peak reading volt meter CD-77
7 Gr Power output Approx. 8 V or over • Tester knob indication: POS50
• Disconnect ECM power source cable.
• Crank with starter motor
• Use Multi circuit tester set.
8 Y/R Communication line A — —
9 B Ground for power — —
10 R Power for sensor Approx. 5V 12 V electric power is supplied to ECM.
11 G/W Diagnosis LED — —
12 B/R High pressure fuel pump (W) Approx. 0.6 V 12 V electric power is supplied to ECM.
13 B/Y High pressure fuel pump (V) Approx. 0.6 V 12 V electric power is supplied to ECM.
14 B/W High pressure fuel pump (U) Approx. 0.6 V 12 V electric power is supplied to ECM.
15 Bl/Y Ignition coil #3 — —
16 Bl Ignition coil #2 — —
17 O Ignition coil #1 — —
18 — — — —
19 R/B CKP sensor — —
20 B/O Cylinder temp. sensor 0.14 – 4.75 V 12 V electric power is supplied to ECM.
• 12 V electric power is supplied to ECM.
Approx. 0.7 V
• Throttle FCT
21 Br/Bl Throttle position sensor
• 12 V electric power is supplied to ECM.
Approx. 4 V
• Throttle WOT
• 12 V electric power is supplied to ECM.
Approx. 5 V
• Stop switch plate IN
22 Bl/O Emergency stop switch
• 12 V electric power is supplied to ECM.
Approx. 0 V
• Stop switch plate OUT
23 — — — —
24 Bl/Y Oil pressure switch — —
1A-32 Engine Control:

Wire
Terminal Circuit Standard voltage Condition / Remarks
color
• 12 V electric power is supplied to ECM.
Approx. 0 V
• Shift into Neutral
25 G or Y/W Neutral switch
• 12 V electric power is supplied to ECM.
Approx. 4.7 V
• Shift into Forward or Reverse
26 Y/B Tachometer — —
27 Bl/W Buzzer — —
28 — — — —
29 Bl/B Oil pressure LED — —
30 G/Y Over heat LED — —
31 W/B IAC valve Approx. 0 V 12 V electric power is supplied to ECM.
32 O/B Fuel injector #1 Approx. 12 V 12 V electric power is supplied to ECM.
33 B/Br Fuel injector #2 Approx. 12 V 12 V electric power is supplied to ECM.
34 R/W Fuel injector #3 Approx. 12 V 12 V electric power is supplied to ECM.

*:Terminal No.12, 13 and 14 standard voltage.

In case of six minutes operation or less from brand new engine, the voltage of the terminal No.12, 13 and 14 will
indicate approx. 8 – 12 V.
 Engine Control: 1A-33

Remote control model

“A”
IFL311110035-01

“A”: ECM terminal

Wire
Terminal Circuit Standard voltage Condition / Remarks
color
1 — — — —
2 Y/Bl CMP sensor Approx. 0.3 V or 5 V Ignition switch ON
3 B Ground for ECM — —
4 Lg/R IAT sensor 0.04 – 4.6 V Ignition switch ON
5 R/Y DC power for ECM Approx. 12 V Ignition switch ON
6 W MAP sensor 0.79 – 4.2 V Ignition switch ON
7 Gr Power output Approx. 12 V Crank with starter motor
8 Y/R Communication line A — —
9 B Ground for power — —
10 R Power for sensor Approx. 5 V Ignition switch ON.
11 G/W Diagnosis LED — —
12 B/R High pressure fuel pump (W) Approx. 0.6 V Ignition switch ON.
13 B/Y High pressure fuel pump (V) Approx. 0.6 V Ignition switch ON.
14 B/W High pressure fuel pump (U) Approx. 0.6 V Ignition switch ON.
15 Bl/Y Ignition coil #3 — —
16 Bl Ignition coil #2 — —
17 O Ignition coil #1 — —
18 — — — —
19 R/B CKP sensor — —
20 B/O Cylinder temp. sensor 0.14 – 4.75 V Ignition switch ON.
• Ignition switch ON
Approx. 0.7 V
• Throttle FCT
21 Br/Bl Throttle position sensor
• Ignition switch ON
Approx. 4 V
• Throttle WOT
• Ignition switch ON
Approx. 5 V
• Stop switch plate IN
22 Bl/O Emergency stop switch
• Ignition switch ON
Approx. 0 V
• Stop switch plate OUT
23 — — — —
24 Bl/Y Oil pressure switch — —
• Ignition switch ON
Approx. 0 V
• Shift into Neutral
25 G Neutral switch
• Ignition switch ON
Approx. 4.7 V
• Shift into Forward or Reverse
26 Y/B Tachometer — —
27 Bl/W Buzzer — —
28 P/G Over revolution LED — —
29 Bl/B Oil pressure LED — —
30 G/Y Over heat LED — —
31 W/B IAC valve Approx. 0 V Ignition switch ON.
32 O/B Fuel injector #1 Approx. 12 V Ignition switch ON.
33 B/Br Fuel injector #2 Approx. 12 V Ignition switch ON.
34 R/W Fuel injector #3 Approx. 12 V Ignition switch ON.
1A-34 Engine Control:

*:Terminal No.12, 13 and 14 standard voltage.

In case of six minutes operation or less from brand new engine, the voltage of the terminal No.12, 13 and 14 will
indicate approx. 8 – 12 V.

ECM Removal and Installation Caution Lamp Inspection

CENFL3121106003 CENFL3121106004
Removal Check for illumination of the caution lamp using the
1) Disconnect lead wire connector from ECM (1). following procedures.
2) Remove the ECM. 1) Disconnect the caution lamp lead wire connector
from engine harness.

NOTICE
1 Failure to correctly supply the voltage will
result in lamp damage.

Do not use battery larger than 2 V to test the

lamp.

2) For tests using 1.5 V power source (or battery),

connect the lamp lead wire to the 1.5 V power
source (or battery) as shown below.
IFL311110036-02
• Gr lead wire to battery (+)
Installation • G/Y, Bl/B, G/W lead wire to battery (–)
Installation is reverse order of removal. When 1.5 V applied
Lamp ON
If out of specification, replace the caution lamp.

Gr

IFL311110037-01

1. Caution lamp

Gr

G/Y, Bl/B, G/W

“A”
IFL311110038-01

“A”: 1.5 V battery

 Engine Electrical Devices: 1C-1

Engine Electrical Devices

Power Head

Precautions
Precaution for Engine Electrical Device
CENFL3121300001
Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions on Engine Control Diagnosis” in Section
1A (Page 1A-1).

General Description
Sensor and Switch Description CMP Sensor
CENFL3121301001
CKP Sensor • The CMP sensor is mounted on the cylinder head.
When the trigger vanes on the cam pulley passes the
• There is one CKP sensor installed below the flywheel
sensor, a voltage signal is generated and sent to the
rotor.
ECM as pulse signal.
When the reluctor bars on the flywheel pass the
This sensor is used to detect piston position.
sensor, a signal (voltage pulse) is generated and sent
to the ECM. This is the fundamental signal used to • Signals received from this sensor are also used by the
judge engine speed and crankshaft angle. ECM to determine sequential fuel injection.
The nine cam pulley trigger vanes provide nine high
• There are 30 reluctor bars. They are located 10
voltage signals from the CMP sensor to the ECM
degrees apart, except at three positions where they
during one camshaft rotation (two rotations of
are 30 degrees apart.
crankshaft).
During one crankshaft rotation, 30 signals are input to
the ECM. • Failure symptom:
Without the CMP sensor signal input, the ECM does
• Failure Symptom:
not output the ignition and fuel injection signals.
Without the CKP sensor signal input, the ECM does
not output the ignition and fuel injection signals.

1
1
2
IFL311130016-01

1. CMP sensor
IFL311130015-01

1. CKP sensor 2. Reluctor bar

2
3

4
Signal
High
Low
5
IFL311130001-02

1. Camshaft (Cam pulley) 4. Magnet

2. Trigger vane 5. CMP sensor
3. Magnet resistive semiconductor
1C-2 Engine Electrical Devices:

ECM cylinder identification:

The cylinders are identified by a calculation of two signals; one from the CKP sensor and one from the CMP sensor.

30 signals / crankshaft 1 rotation

CKP sensor
signal

CMP sensor
signal
CMP sensor - 9 signals / 720° (crankshaft 2 rotation)

TDC
No.1 cylinder Cm. Ep. Ex. In.
TDC
No.3 cylinder In. Cm. Ep. Ex.
TDC
No.2 cylinder Ep. Ex. In. Cm.

Cm.: Compression, Ep.: Explosion, Ex.: Exhaust, In.: Intake,

IAJ611130002-01

Cylinder Temperature Sensor

The cylinder temperature sensor is installed on the (k )
cylinder (top side) and is used to detect the cylinder
temperature.
This is a thermistor type sensor (resistance of which Resistance
changes depending on temperature) and inputs a signal
to the ECM as a voltage value. This signal is used to
compensate the fuel injection duration, ignition timing,
etc.
This sensor is also used to detect engine over-heat as
the ECM detects both the temperature and temperature Temperature (C°)
change rate (gradient temp.-temperature rise vs. time). I9J011130003-02

IAT Sensor
The IAT sensor is installed on the air intake silencer case
and is used to detect the intake air temperature.
This sensor is the same type as the cylinder temperature
sensor, and inputs a signal to the ECM as a voltage
value.
This signal is used to compensate the fuel injection
1 duration.

IFL311130017-01

1. Cylinder temp. sensor 1

IFL311130018-01

1. IAT sensor
 Engine Electrical Devices: 1C-3

MAP Sensor Neutral Switch

The MAP sensor is installed on the intake manifold and The neutral switch is installed on the clutch shaft holder
used to detect the intake manifold pressure. and is used to detect the shift position.
This sensor inputs the intake manifold pressure to the This switch is “ON” in neutral and “OFF” in forward or
ECM as a voltage value. reverse.
This input signal is used as the fundamental signal to The ECM performs the following controls based on the
determine fuel injection duration, ignition timing, etc. neutral switch signal:
• Fuel injection and ignition are not performed when the
shift is in forward or reverse at the time of engine start.
(Start-in-gear protection. Refer to “Start-In-Gear
Protection System Description” in Section 1I (Page 1I-
2).)
1
• When the shift lever is in neutral, fuel injection is
controlled so that the engine speed does not exceed 3
000 r/min.
• After shifting into forward or reverse from neutral, the
IAC valve is controlled to increase intake air to
prevent unstable engine idle or stalling.
IFL311130019-01

1. MAP sensor

Throttle Position Sensor (TPS)

The TPS is installed on the throttle body and detects the
degree of throttle opening. The throttle shaft is 1
interlocked with the TPS shaft.
This sensor is a variable resistor, changing resistance
(Ohms) in accordance with the throttle opening.
The varying resistance value is converted to voltage and
input to the ECM.
Based on the TPS voltage, the ECM calculates the idle
IFL311130021-01
and throttle opening position to determine the control
modes of the various controls systems (Idle air control, 1. Neutral switch

fuel injection control system, etc.).

Emergency Stop Switch
When the cord from the plate of the switch is secured to
the operator, the plate will be pulled off if the operator is
suddenly thrown overboard.
1
The circuit of emergency stop switch will be closed when
the plate is removed.
Then the ECM does not provide fuel injector operating
signal, ignition signal and fuel pump operating signal.

Failure Symptoms
A switch short circuit will not allow the motor to start.

IFL311130020-01

1. TPS

IFL311130049-02

1. Emergency stop switch

1C-4 Engine Electrical Devices:

ECM Power Source

CENFL3121301002 1 2
The AC output from the ECM power source coil is
rectified to DC power by the rectifier/regulator No.1.
The DC power inputs to ECM through ECM No.5
terminal, and it is supplied to the engine control system. 3

IFL311130002-02

1. ECM power source coil 3. Rectifier/regulator No.1

2. Battery charge coil 4. ECM

Component Location
Location of Sensor and Switch
CENFL3121303001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-7).
 Engine Electrical Devices: 1C-5

Service Instructions
Resistance Check
CENFL3121306001

Special tool
: 09900–25008 (Multi circuit tester set)
Tester knob indication
Resistance (Ω)
1) Stop the engine.
2) Disconnect battery cables from battery.
3) Disconnect wire harness connector from ECM.
4) Connect the tester probes to terminal (wire harness side) and measure resistance according to the “Resistance
Table” (Page 1C-5).

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
18
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
18
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

2
1

IFL311130003-01

1. Engine main wire harness 2. ECM connector

Resistance Table
Terminal for tester probe
Circuit Standard resistance (at 20 °C)
connection
Refer to “ECM Power Source
ECM power source coil Coil Inspection” in Section 1K 1.1 – 1.7 Ω
(Page 1K-7).
CKP sensor 19 (R/B) to 3 (B) 168 – 252 Ω
Fuel injector No.1 32 (O/B) to 7 (Gr)
Fuel injector No.2 33 (B/Br) to 7 (Gr) 10 – 14 Ω
Fuel injector No.3 34 (R/W) to 7 (Gr)
IAC valve 31 (W/B) to 7 (Gr) 22 – 26 Ω
0 °C (32 °F): 5.3 – 6.6 kΩ
25 °C (77 °F): 1.8 – 2.3 kΩ
IAT sensor 4 (Lg/R) to 3 (B) 50 °C (122 °F): 0.73 – 0.96 kΩ
75 °C (135 °F): 0.33 – 0.45 kΩ
(Thermistor characteristic)
0 °C (32 °F): 28.5 – 31.5 kΩ
25 °C (77 °F): 10.0 – 11.5 kΩ
Cylinder temperature sensor 20 (B/O) to 3 (B) 50 °C (122 °F): 4.0 – 4.8 kΩ
75 °C (135 °F): 1.8 – 2.2 kΩ
(Thermistor characteristic)
1C-6 Engine Electrical Devices:

ECM Power Source Input Voltage Inspection CKP Sensor Peak Voltage Inspection
CENFL3121306002 CENFL3121306004
Requirements for input voltage measurement
Special tool
• In case of cranking with starter motor: : Stevens peak reading voltmeter CD-77
Use multi circuit tester set.
Tester knob indication
Special tool SEN 50
: 09900–25008 (Multi circuit tester set)
1) Disconnect the wire harness connector from ECM.
Tester knob indication
2) Connect the tester probe (“–”, Black) to No.3
DCV
terminal as shown in figure.
• In case of cranking with recoil starter: 3) Connect the tester probe (“+”, Red) to No.19
Use peak reading volt meter. terminal.
Special tool Tester probe connection
: Stevens peak reading voltmeter CD-77 Red (+) Black (–)
No.19 (R/B) No.3 (B)
Tester knob indication
POS 50
1) Disconnect the wire harness connector from ECM.
2) Connect the tester probe (“–”, Black) to No.9
terminal (or to body ground) as shown in figure. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

3) Connect the tester probe (“+”, Red) to No.5 terminal. 18

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Tester probe connection

Red (+) Black (–)
No.5 (R/Y) No.9 (B) (or GND) IFL311130005-01

4) Remove all spark plugs.

5) Crank with the starter motor or recoil starter, then
measure voltage.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
CKP sensor peak voltage
3 V or over
18
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
6) If measurement is out of specification,
• 1st, check CKP sensor air gap
IFL311130004-01 • 2nd, check wire harness for open and short.
4) Remove the all spark plugs. If wire harness and air gap are in good condition,
5) Crank with the starter motor or recoil starter, then replace CKP sensor and recheck.
measure voltage.
ECM power source input voltage
8 V or over
6) If measurement is out of specification.
• 1st, check wire harnesses for open and short.
• 2nd, check rectifier/regulator No.1.
If wire harnesses, rectifier/ regulator No1 test “good”,
replace ECM power source coil and recheck.

ECM Power Source Coil Removal and

Installation
CENFL3121306003
Refer to “Battery Charge Coil Removal and Installation”
in Section 1K (Page 1K-5).
 Engine Electrical Devices: 1C-7

CKP Sensor Removal and Installation Installation

CENFL3121306005 Installation is reverse order of removal with special
Removal attention to the following steps.
1) Remove the recoil starter. • Install CKP sensor (1), then tighten sensor mounting
Refer to “Recoil Starter Removal and Installation” in bolts securely.
Section 1J (Page 1J-3).
2) Disconnect lead wire connector from ECM (1), then
remove ECM.

IFL311130025-01
1 • After installing CKP sensor, check air gap between
CKP sensor and flywheel reluctor bars.
IFL311130022-01

3) Disconnect the CKP sensor lead wire connector (2). CKP sensor air gap “a”
1.0 mm (0.04 in)

3
2

1
“a”
1
IFL311130023-01
IFL311130026-03
4) Remove the bolts and CKP sensor (3).
1. CKP sensor 3. Thickness gauge
2. Flywheel reluctor bar

IFL311130024-01
1C-8 Engine Electrical Devices:

Cylinder Temp. Sensor Removal and 5) Loosen and remove the cylinder temp. sensor (4).
Installation
CENFL3121306006
Removal
1) Remove the recoil starter.
Refer to “Recoil Starter Removal and Installation” in
Section 1J (Page 1J-3).
2) Remove the bolt and cam pulley cover (1).

IFL311130030-01

Installation
Installation is reverse order of removal.
• Clean mating surface of sensor and cylinder.
• Tighten sensor to specified torque.

IFL311130027-01
Tightening torque
Cylinder temp. sensor (a): 9 N·m (0.9 kgf-m, 6.5
3) Disconnect lead wire connector from ECM (2), then
lbf-ft)
remove ECM.

(a)

IFL311130031-01
IFL311130028-01
• Connect connector to sensor securely.
4) Disconnect the cylinder temp. sensor lead wire
connector (3). • Check to ensure that all removed parts are back in
original position.
• Check wire routing.
Refer to “Wiring Harness Routing Diagram” in Section
3 4A (Page 4A-7).

IFL311130029-01
 Engine Electrical Devices: 1C-9

Cylinder Temp. Sensor Inspection IAT Sensor Removal and Installation

CENFL3121306007 CENFL3121306008
1) Remove the cylinder temperature sensor. Removal
Refer to “Cylinder Temp. Sensor Removal and 1) Disconnect the IAT sensor lead wire connector.
Installation” (Page 1C-8). 2) Remove IAT sensor (1).
2) Immerse temperature sensing part of cylinder temp.
sensor in water.
3) Measure resistance between sensor terminals while
heating water gradually.
1
4) If measured resistance does not change in the
proportion indicated, replace sensor.
Cylinder temp. sensor specification
Water
temperature: 0 (32) 25 (77) 50 (122) 75 (135)
°C (°F)
Resistance
28.5 – 31.5 10 – 11.5 4.0 – 4.8 1.8 – 2.2 IFL311130032-01
(kΩ)
Installation
Installation is reverse order of removal with special
1 attention to the following steps.
• Check to ensure that all removed parts are back in
original position.
• Check wire routing.
Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-7).

IAT Sensor Inspection

CENFL3121306009
2
I9J011130051-01 1) Remove the IAT sensor.
Refer to “IAT Sensor Removal and Installation”
1. Thermometer 2. Heater
(Page 1C-9).
2) Immerse temperature sensing part of IAT sensor in
water.
3) Measure resistance between sensor terminals while
heating water gradually.
4) If measured resistance does not change in the
proportion indicated, replace sensor.
Resistance

IAT sensor specification

Water
temperature: 0 (32) 25 (77) 50 (122) 75 (135)
°C (°F)
Resistance 0.73 – 0.33 –
5.3 – 6.6 1.8 – 2.3
Temperature (kΩ) 0.96 0.45
I9J011130008-02

5) Reinstall the cylinder temp. sensor.

Refer to “Cylinder Temp. Sensor Removal and
Installation” (Page 1C-8).
1C-10 Engine Electrical Devices:

CMP Sensor Inspection

CENFL3121306011
1 1) Stop the engine.
2) Remove the bolt and CMP sensor (1).

2
I9J011130007-03

1. Thermometer 2. Heater

IFL311130034-01

3) On the tiller handle model; connect the ECM power

source cable to SDS communication connector.
Special tool
Resistance

(A): 09933–08910 (ECM power source

cable)

(A)

Temperature
I9J011130008-02

5) Reinstall the IAT sensor.

Refer to “IAT Sensor Removal and Installation”
(Page 1C-9).

CMP Sensor Removal and Installation

CENFL3121306010 IFL311130035-01
Removal
4) Connect the 34-pin test cord between ECM and wire
1) Disconnect the CMP sensor lead wire connector at harness as shown in figure.
sensor.
Special tool
2) Remove the bolt (1) and CMP sensor (2).
(B): 09930–89290 (18 pin & 34 pin test
cord)

3
2
1
(B)

1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
14 15 16 17 31 32 33 34

IFL311130033-02

Installation 1
Installation is reverse order of removal. IFL311130006-01

• Install CMP sensor, then tighten mounting bolt 1. Wire harness 2. White connector 3. ECM
securely.
• Connect sensor lead wire connector to CMP sensor.
 Engine Electrical Devices: 1C-11

5) Connect the ECM power source cable to 12 V MAP Sensor Removal and Installation
battery. CENFL3121306012
Removal
6) On the remote control model; turn the ignition switch
ON. 1) Remove the bolt (1) and MAP sensor (2).
7) Connect the tester probe (“+”, Red) to No.2 terminal. 2) Disconnect lead wire connector (3) at MAP sensor.
8) Connect the tester probe (“–”, Black) to No.3
terminal (or to body ground).
Special tool 3
: 09900–25008 (Multi circuit tester set)
2
Tester knob indication
DC Voltage 1

34-pin test cord (White connector)

2
IFL311130036-01

2 3
Installation
Installation is reverse order of removal.
• Connect sensor lead wire connector to MAP sensor.
• Install MAP sensor, then tighten mounting bolt
securely.
IFL311130007-01

9) Measure the voltage when the tip of a steel MAP Sensor Output Voltage Inspection
CENFL3121306013
screwdriver is brought near and then pulled away
1) Connect the 34-pin test cord between ECM and wire
from the sensor tip.
harness as shown in figure.
When screwdriver is brought near
Special tool
Approx. 5 V
(A): 09930–89290 (18 pin & 34 pin test
When screwdriver is pulled away cord)
Approx. 0.3 V
3
5

(A)

1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
4 14 15 16 17 31 32 33 34
IDK111130018-02

4. Screw driver 5. CMP sensor

1
10) If the voltage does not change in the above test, IFL311130008-02
check wire harnesses for open and short.
1. Wire harness 2. White connector 3. ECM
If wire harnesses are in good condition, replace CMP
sensor and recheck.
11) Reinstall CMP sensor.
1C-12 Engine Electrical Devices:

2) On the tiller handle model; connect the ECM power 34-pin test cord (White connector)
source cable to SDS communication connector and
12 V battery.
6
Special tool
(B): 09933–08910 (ECM power source
cable)

IFL311130009-01
(B)

Special tool
: 09900–25008 (Multi circuit tester set)
Tester knob indication
DC Voltage ( )
If out of specification, check wire harnesses for open
and short. If wire harnesses are in good condition,
IFL311130037-01 replace MAP sensor and recheck.
3) Remove the bolt and MAP sensor (1) from intake 7) Reinstall MAP sensor.
manifold. Refer to “MAP Sensor Removal and Installation”
(Page 1C-11).

IAC Valve Removal and Installation

CENFL3121306014

1
Removal
1) Remove the bolts and air duct (1).

IFL311130038-01

4) On the remote control model; turn the ignition switch

ON.
5) Connect vacuum pump gauge (with hose) to MAP 1
sensor as shown in figure.
Special tool IFL311130039-01
(C): 09917–47011 (Vacuum pump gauge) 2) Remove the bolt and MAP sensor (2).

(C)

IDK111130002-03

6) While applying negative pressure (vacuum) to MAP

sensor, measure “6” terminal voltage.
MAP sensor output voltage change IFL311130040-01

Negative pressure: 0 40 80
kPa (kg/cm2, mmHg) (0, 0) (0.4, 300) (0.8, 600)
“6” terminal voltage (V) 4.00 2.42 0.84

(at 759.8 mmHg, 101.3 kPa, 29.91 inHg

barometric pressure.)
 Engine Electrical Devices: 1C-13

3) Disconnect IAC valve lead wire connector at IAC Installation

valve (3). Installation is reverse order of removal with special
Remove the bolts securing IAC valve bracket (4). attention to the following steps.
• Connect the inlet/outlet hose(1)/(2) to IAC valve.
Install the IAC valve, then tighten mounting bolts
securely.
3

IFL311130041-01
2
1
4) Remove the IAC valve (3) from intake manifold, then
disconnect air inlet hose (5) and outlet hose (6) from
IAC valve. IFL311130043-01

5
6

IFL311130042-01 IFL311130044-01

• Install the MAP sensor.

1C-14 Engine Electrical Devices:

IAC Valve Inspection TPS Inspection

CENFL3121306015 CENFL3121306016
1) Remove the bolts and air duct (1). 1) Stop the engine.
2) On the tiller handle model; connect the ECM power
source cable to SDS communication connector.
Special tool
(A): 09933–08910 (ECM power source
cable)

1
(A)

IFL311130045-01

2) Disconnect connector (2) at IAC valve.

3) Check the coil of IAC valve for resistance.
If out of specification, replace IAC valve.
IAC valve resistance
Standard: 22 – 26 Ω IFL311130048-01

3) Connect the 34-pin test cord between ECM and wire

harness as shown in figure.
Special tool
2 (B): 09930–89290 (18 pin & 34 pin test
cord)

(B)

IFL311130046-01
3 4

1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
14 15 16 17 31 32 33 34

2
IFL311130010-01

1. ECM 3. White connector

2. Wire harness 4. Black connector

4) Connect the ECM power source cable to 12 V

battery.
IFL311130047-02

4) Connect the IAC valve lead wire connector, then 5) On the remote control model; turn the ignition switch
install air duct. ON.
 Engine Electrical Devices: 1C-15

6) Connect tester probe (“+”, Red) to No.21 terminal. Emergency and Engine Stop Switch Inspection
CENFL3121306017
7) Connect tester probe (“–”, Black) to No.3 terminal (or
to body ground) 1) Disconnect the emergency stop switch lead wire.
34-pin test cord (White connector) 2) Check the continuity / infinity between the wiring
leads under the condition shown below.
3
Special tool
(A): 09900–25008 (Multi circuit tester set)
3
Tester knob indication
Continuity ( )
IFL311130011-01 Tester probe connection Tester
Red (+) Black (–) indicates
34-pin test cord (Black connector) Lock plate
Infinity
installed
4 Lock plate
Continuity
removed
Bl/R B
21 Lock plate
installed and
Continuity
stop button
depressed

IFL311130012-01

8) Check for sensor output voltage. (A)

Slowly move the throttle control grip (or remote
control handle) to open, and check if voltage
changes linearly within specification, according to B
throttle valve opening angle.
Sensor output voltage
FCT position: Approx. 0.7 V Bl/R
WOT position: Approx. 3.8 V
Special tool
: 09900–25008 (Multi circuit tester set) IFL311130013-01

Tester knob indication

DC Voltage ( )

NOTICE
The throttle body will lose its original (A)
performance if it has been disassembled and
reassembled.
B
Do not try to adjust or remove any of the
throttle body component parts (Throttle
position sensor, throttle valve, throttle stop
screw, etc.). Bl/R
These components have been factory IFL311130014-01

adjusted to precise specifications. 3) If out of specification, replace the switch.

9) If out of specification, check wire harness for open

and short. If wire harnesses are in good condition,
replace the throttle body and recheck.
1D-1 Power Unit Mechanical:

Power Unit Mechanical

Power Head

General Description
Power Unit Construction Description
CENFL3121401001
The engine is direct water-cooled, in-line 3-cylinders, 4-stroke cycle gasoline unit, SOHC (single overhead camshaft)
valve mechanism with “V” type valve configuration and 6 valves (2 valves per cylinder).
The camshaft is mounted over the cylinder head; it is driven by crankshaft through timing belt (cogged belt).
Unlike conventional overhead valve (OHV) engines, this engine has no push rods. Thus, valve movement is more
direct and enables them to follow crankshaft rotation without any delay.

Cylinder Number
Cylinder number is as mentioned in figure.

IFL311140078-02

1. No.1 cylinder 2. No.2 cylinder 3. No.3 cylinder

Diagnostic Information and Procedures

Cylinder Compression Check
CENFL3121404001
Refer to “Cylinder Compression Pressure Check” in Section 0B (Page 0B-23).

Oil Pressure Check

CENFL3121404002
Refer to “Oil Pressure Check” in Section 0B (Page 0B-22).
 Power Unit Mechanical: 1D-2

Service Instructions
Valve Clearance Inspection 4) Remove the check valve (5) from element case.
CENFL3121406001
Refer to “Valve Clearance Inspection and Adjustment” in
Section 0B (Page 0B-8).

Recoil Starter Removal and Installation

CENFL3121406002
Refer to “Recoil Starter Removal and Installation” in
Section 1J (Page 1J-3).

Air Cleaner Element Removal and Installation

CENFL3121406003
Removal 5
1) Disconnect IAT sensor lead wire connector (1) at IFL311140020-02
sensor.
Installation
Installation is reverse order of removal.

Air Cleaner Element Inspection

CENFL3121406004
• Visually check that air cleaner element is not
excessively dirty, oily, or damaged.
• Clean the element with compressed air from its air
1
outlet side.

NOTE
IFL311140017-02 The air cleaner element is a serviceable item.
2) Remove the four screws (2) securing air cleaner Suzuki recommends that clean the element
element case (3), then detach the element case. every 200 hours or more frequent on severe
use.

IFL311140018-02

3) Remove the element (4) from air cleaner element

IFL311140021-02
case.

IFL311140019-02
1D-3 Power Unit Mechanical:

Cylinder Head Cover Removal and Installation 5) Remove the bolts and fuel filter bracket (6) (with fuel
CENFL3121406005 filter (7)).
Removal
Before removing cylinder head cover, disconnect
battery cables from battery.
1) Remove both lower side covers.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
2) Remove the bolt (1) and cam pulley cover (2).

7
6
2

IFL311140025-02

6) Loosen the clip (8), then disconnect the breather

hose (9) from cylinder head cover.

1
IFL311140022-02

3) Disconnect ignition primary coil lead wire

connectors.
Remove the bolts (3) and all ignition coils (4). 9

4 IFL311140026-02
3
7) Remove the eight bolts securing cylinder head cover
(10) to the cylinder head, then remove the cylinder
head cover with lower cover holder (11).
4 3

10

IFL311140023-02

4) Remove the bolts securing low pressure fuel pump

(5), then remove the fuel pump from cylinder head
cover.
Refer to “Low Pressure Fuel Pump Removal and
Installation” in Section 1G (Page 1G-23). 11

IFL311140027-03

8) Remove the bolts and cover gasket (12).

12

IFL311140024-02

IFL311140028-02
 Power Unit Mechanical: 1D-4

Installation • Install cylinder head cover (2) to cylinder head, then

Installation is reverse order of removal with special tighten cylinder head cover bolts to specified torque.
attention to the following steps.
Tightening torque
• Clean sealing surface on cylinder head and cover. Cylinder head cover bolt (a): 10 N·m (1.0 kgf-m,
• Remove oil and dust from sealing surfaces. 7.2 lbf-ft)
• Install new cylinder head cover gasket (1) to head
cover (2), then secure with bolts.

NOTE
(a)
Examine cylinder head cover gasket for
damage.
2
Always replace gasket with new one.

1
IFL311140030-03

“7” “6”

“2” “3”

2
IFL311140029-02
“4” “1”

“5” “8”
IFL311140225-02

• Perform the following final assembly checks to ensure

proper and safe operation.
– All parts removed have been returned to their
original positions.
– Wire and hose routing matches service manual
illustration.
Refer to “Fuel/Water Hose Routing” in Section 4B
(Page 4B-1) and “Wiring Harness Routing
Diagram” in Section 4A (Page 4A-7).
– No oil leakage is evident during final test running.
1D-5 Power Unit Mechanical:

Intake Manifold and Throttle Body Components

CENFL3121406006

7 (b)

2
6 11
12

(b)
4

10

(b)
9

(a)

IFL311140001-04

1. Air intake duct 6. IAC air inlet hose 11. Intake manifold
2. Air intake silencer case 7. IAC air outlet hose 12. Gasket
3. Air cleaner element case 8. Seal (DF30A) : 11 N⋅m (1.1 kgf-m, 8.0 lbf-ft)
Restrictor (DF25A)
4. Air cleaner element 9. Throttle body : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft)
5. IAC valve 10. Gasket
 Power Unit Mechanical: 1D-6

Intake Manifold Removal and Installation 6) Disconnect the IAC lead wire connector at IAC valve.
CENFL3121406007 Remove the bolts securing IAC valve bracket (6).
Removal
1) Relieve fuel pressure.
Refer to “Fuel Pressure Relief Procedure” in Section
1G (Page 1G-15).
2) Disconnect battery cables from battery.
3) Remove the lower side covers.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
4) Remove the air cleaner element case (1), air intake
duct (2) and recoil starter (3). 6
Remove the two bolts (4) securing air intake silencer
case. IFL311140034-02

7) Lift IAC valve up, then disconnect IAC air inlet hose
3 (7) from IAC valve.
2

7
IFL311140031-02

IFL311140035-02

8) Remove the air intake silencer case (8) from throttle

body, then disconnect the breather hose (9) from
silencer case.
4

IFL311140032-02

5) Remove the bolt and MAP sensor (5).

9

IFL311140036-02

9) Remove the throttle link rod (10) from throttle body

5 (11).

11

IFL311140033-02

10

IFL311140037-02
1D-7 Power Unit Mechanical:

10) Disconnect TPS lead wire connector (11) at sensor. 14) Disconnect high pressure fuel pump lead wire
Remove the bolts and throttle body (10). connector (16).

11

16

10

IFL311140038-02 IFL311140042-02

11) Remove the fuel delivery pipe (12) with fuel injectors. 15) Remove the bolt (17) securing high pressure fuel
Refer to “Fuel Injector Removal and Installation” in pump bracket.
Section 1G (Page 1G-21). Disconnect water discharge hose (18) from pilot
water tube.

17

12

18

IFL311140039-03

12) Remove the bolt and throttle drum (13). IFL311140043-02

Loosen the lock nuts, then remove the throttle cables 16) Remove the bolt and oil level dipstick tube (19).
(14) from cable bracket. Note the position before removing O-ring (20).

14
19
13
19

20

IFL311140040-03 IFL311140226-03

13) Remove the fuel inlet hose (15) from intake manifold.

15

IFL311140041-02
 Power Unit Mechanical: 1D-8

17) Disconnect the water hose (21) from driveshaft 20) Remove the two bolts and fuel vapor separator (24).
housing.

24

21

IFL311140048-03

IFL311140044-03 21) Remove the bolt and water cooler (25).

18) Disconnect the fuel inlet hose (22) from fuel vapor
separator.

22
25

IFL311140049-03

22) Disconnect IAC air outlet hose (26) from intake

IFL311140045-03 manifold.
19) Remove the four bolts and two nuts securing intake
manifold.
Remove the intake manifold (23).

26

IFL311140050-03
23

IFL311140046-04

23

IFL311140047-03
1D-9 Power Unit Mechanical:

Installation • Install the intake manifold assembly, then tighten bolts

Installation is reverse order of removal with special and nuts in ascending order of numbers.
attention to the following steps.
Tightening torque
• Install the high pressure fuel pump and fuel vapor Intake manifold bolt/nut (a): 23 N·m (2.3 kgf-m,
separator to intake manifold. 16.5 lbf-ft)
Refer to “Fuel Vapor Separator Removal and
Installation” in Section 1G (Page 1G-16).
“3”

“1”

“2”

“4”
IFL311140053-02

IFL311140051-02

NOTICE
Air leakage will induce a lean air / fuel mix “5”
which will result in severe engine damage.

Do not reuse gasket once removed. Always

use a new gasket.
“6”
• Install new gaskets (1).

IFL311140054-02

• Install the new gasket (2).

1 NOTICE
Air leakage will induce a lean air / fuel mix
which will result in severe engine damage.

Do not reuse gasket once removed. Always

use a new gasket.

IFL311140052-03

IFL311140055-02
 Power Unit Mechanical: 1D-10

• Install the throttle body (3) to intake manifold, then • Connect the IAC air inlet hose (8) to IAC valve (9),
tighten the bolts to specified torque. then install the IAC valve.
Tightening torque
Throttle body bolt (b): 11 N·m (1.1 kgf-m, 8.0 lbf-
ft) 9

IFL311140059-02
(b) • Install the MAP sensor (10).

IFL311140056-03

• Install the fuel delivery pipe (4) with fuel injectors.

Refer to “Fuel Injector Removal and Installation” in
Section 1G (Page 1G-21). 10

IFL311140060-02

• Perform the following final assembly checks to ensure

proper and safe operation.
– All parts removed have been returned to their
original positions.
IFL311140057-02 – Wire and hose routing matches service manual
• Connect the breather hose (5) and IAC air inlet hose illustration.
(6) to silencer case (7), then install the silencer case Refer to “Wiring Harness Routing Diagram” in
to throttle body. Section 4A (Page 4A-7) and “Fuel/Water Hose
Routing” in Section 4B (Page 4B-1).
7 – No fuel leakage is evident when fuel system is
pressurized.
6 Refer to “Fuel Leakage Check Procedure” in
Section 1G (Page 1G-15).

Throttle Body Removal and Installation

CENFL3121406008
5 Refer to “Intake Manifold Removal and Installation”
(Page 1D-6).

IFL311140058-02

IFL311140061-03
1D-11 Power Unit Mechanical:

Throttle Body Inspection Camshaft Pulley / Crankshaft Timing Pulley /

CENFL3121406009
NOTICE
Timing Belt Removal and Installation
CENFL3121406010
The throttle body will lose its original Removal
performance if it has been disassembled and 1) Remove the cylinder head cover.
reassembled. Refer to “Cylinder Head Cover Removal and
• Do not try to disassemble the throttle body. Installation” (Page 1D-3).
• Do not try to adjust or remove any of the NOTICE
throttle body component parts (Throttle
After the timing belt has been removed,
position sensor, throttle valve, throttle
independently turning cam pulley or
stop screw, etc.).
crankshaft will cause interference between
These components have been factory
piston and valve, which cause damage to
adjusted to precise specifications.
these related parts.
• Clean throttle body bore by compressed air.
Do not rotate the cam pulley and/or
• Check that if there is any foreign dust or carbon crankshaft with timing belt removed.
caught at the passage between throttle valve and
throttle body housing.
NOTE
If there is, clean the passage inside of throttle body by
compressed air thoroughly. To prevent valve damage, loosen valve
adjusting screws fully before removing
• Check that throttle valve moves smoothly.
timing belt.

2) Loosen all valve adjusting lock nut (1).

Loosen the six valve adjusting screws (2) fully.
Leave the screws in place.

1
1

IFL311140062-02 2

IFL311140064-02

3) Remove the flywheel (3).

Refer to “Flywheel Removal and Installation” in
Section 1K (Page 1K-4).

IFL311140063-02

IFL311140065-02
 Power Unit Mechanical: 1D-12

4) Remove the bolts securing battery charge coil (4). 7) Using flat blade screw driver, drive locking edges of
Lift battery charge coil from cylinder block and lay it. lock washer (11) downward, and then remove timing
pulley nut (10).

NOTE
4
The pulley nut has been applied the thread
lock cement.
Slightly tap the pulley nut to
counterclockwise using a flat blade screw
driver and a hammer before loosening the
nut.

Special tool
(A): 09911–49310 (Crankshaft holder)
IFL311140066-02

5) Remove the timing belt (5).

Refer to “Timing Belt Replacement” in Section 0B
(A)
(Page 0B-10).

10

11
IFL311140069-03

8) Remove the lock washer (11), upper guide (12),

5 timing pulley (13), key (14).
IFL311140067-02

6) Remove the bolt (6), washer (7), camshaft pulley (8)

and key (9).
11

8 12
6
14
7
9 13
11
6 12
13
7 IFL311140070-05

8
IFL311140068-03
1D-13 Power Unit Mechanical:

Installation 4) Apply thread lock to timing pulley nut (5).

Installation is reverse order of removal with special
: Thread lock cement 99000–32050
attention to the following steps.
(SUZUKI Thread Lock 1342 (50 g))
Crankshaft timing pulley 5) Install timing pulley nut (5).
1) Install key (1). Tighten timing pulley nut to specified torque using
special tool.
2) Install timing pulley (2) and upper guide (3) with
direction as shown. Special tool
3) Install lock washer (4) with direction as shown. (A): 09911–49310 (Crankshaft holder)

NOTE Tightening torque

Crankshaft timing pulley nut (a): 50 N·m (5.0 kgf-
• Timing pulley direction: m, 36.0 lbf-ft)
Position the PUNCH mark to the upper
side.
• Belt guide direction:
Install the belt guide with flanges towards
outside.

4 5 (a)

IFL311140073-03
3
1
2
2 (A)

IFL311140071-06

IFL311140074-02

6) Bend the lock washer edge toward nut for locking.

3
IFL311140072-03

IFL311140075-02
 Power Unit Mechanical: 1D-14

Camshaft pulley 2) Check that the PUNCH mark “I” on cam pulley aligns
1) Install the key (1), camshaft pulley (2), washer (3) with the INDEX mark on cylinder head.
and bolt (4), then tighten camshaft pulley bolt to
specified torque.
5
Tightening torque 4
Camshaft pulley bolt (a): 30 N·m (3.0 kgf-m, 22
lbf-ft)

IFL311140228-04

4. Punch mark ( ) 5. INDEX mark

1
NOTE
IFL311140076-02
If it is necessary to rotate the camshaft after
removing timing belt, turn crankshaft
clockwise and position the flywheel key (1)
within an angle of 45° to 60° from TDC before
2
4 (a) rotating the camshaft as shown in the
following figure and keep the valves from
coming in contact with pistons.

IFL311140077-02

Timing belt
1) Make sure that the key groove for flywheel on
crankshaft and the PUNCH mark on lock washer for
timing pulley nut align with the INDEX mark on
cylinder block. “a”
IFL311140229-03

1. Flywheel key “a”: 45° – 60°

1

IFL311140227-04

1. Key groove 2. Punch mark ( ) 3. INDEX mark

1D-15 Power Unit Mechanical:

3) Install the timing belt on the crankshaft timing pulley Battery charge coil and flywheel
first, then the cam pulley. • Install the battery charge coil and flywheel.
Refer to “Battery Charge Coil Removal and
NOTE
Installation” in Section 1K (Page 1K-5) and “Flywheel
The timing belt must be installed with the Removal and Installation” in Section 1K (Page 1K-4).
arrow mark on the timing belt toward the
direction of rotation. Cylinder head cover

NOTE
Before installing cylinder head cover, check
valve clearance.
Refer to “Valve Clearance Inspection and
Adjustment” in Section 0B (Page 0B-8).

• Install cylinder head cover.

Refer to “Cylinder Head Cover Removal and
Installation” (Page 1D-3).

Final assembly check

IFL311140230-02 • All parts removed have been returned to their original
4) Turn crankshaft normal running direction two positions.
revolutions and make sure following items. • Check wire routing.
• Punch mark on the timing pulley nut lock washer Refer to “Wiring Harness Routing Diagram” in Section
is aligned with the INDEX mark on cylinder block. 4A (Page 4A-7).
• Key groove of flywheel on crankshaft is aligned
with the INDEX mark on cylinder block. Power Unit Removal and Installation
CENFL3121406011
• PUNCH mark “I” on the cam pulley is aligned with Removal
the INDEX mark on the cylinder head block. Before removing power unit:
• Relieve fuel pressure.
Refer to “Fuel Pressure Relief Procedure” in Section
1 1G (Page 1G-15).
• Disconnect battery cables from battery.
• Drain engine oil.
2 1) Remove both lower side covers.
Refer to “Lower Side Cover Removal and
3 Installation” in Section 2A (Page 2A-3).
2) Remove the screws and air cleaner element case
(1).
IFL311140237-01 Refer to “Air Cleaner Element Removal and
Installation” (Page 1D-2).

5
4

IFL311140079-02
IFL311140232-03

1. Key groove 4. Punch mark ( )

2. Punch mark ( ) 5. INDEX mark
3. INDEX mark
 Power Unit Mechanical: 1D-16

3) Remove the recoil starter (2). 6) Remove the bolts securing air intake silencer case
Refer to “Recoil Starter Removal and Installation” in (7).
Section 1J (Page 1J-3).

IFL311140083-03

IFL311140080-02 7) Remove the air intake silencer case from throttle

4) Remove the bolt and MAP sensor (3). body, then disconnect breather hose (8) from intake
Remove the cable clamp (4) from bracket. silencer case.
Disconnect IAC lead wire connector at IAC valve (5).
Remove the bolts securing IAC valve.

3
8

IFL311140084-02

8) Remove the bolts and fuel delivery pipe (9) with fuel
IFL311140081-03 injectors.
5) Lift IAC valve up, then disconnect IAC air inlet hose Refer to “Fuel Injector Removal and Installation” in
(6) from IAC valve. Section 1G (Page 1G-21).

IFL311140082-02 IFL311140085-02
1D-17 Power Unit Mechanical:

9) On the tiller handle model;

Remove the bolt and throttle drum (10) from intake
manifold.
Remove the throttle cables (11) from cable bracket. 14

11

10

IFL311140088-03

12) Disconnect the fuel inlet hose (15) and outlet hose
(16) from low pressure fuel pump (17).
Remove the two bolts securing low pressure fuel
IFL311140086-03 pump, then detach the low pressure fuel pump from
10) On the remote control model; cylinder head cover.
Remove the bolt and throttle link lever (12) from Refer to “Low Pressure Fuel Pump Removal and
intake manifold. Installation” in Section 1G (Page 1G-23).

16 15

12

17
IFL311140234-02 IFL311140089-02

11) Remove the bolts and oil level dipstick tube (13). 13) Remove the bolts and fuel filter bracket (18) (with
Remove the intake manifold assembly (14). fuel filter).
Refer to “Intake Manifold Removal and Installation”
(Page 1D-6).

14

18

IFL311140090-02

13
IFL311140087-02
 Power Unit Mechanical: 1D-18

14) Remove the cotter pin (19) and washer (20), then 17) Remove the bolts and starter motor band (26).
detach the clutch lever link rod (21) from clutch shaft Remove the starter motor (27).
lever (22). Refer to “Starter Motor Removal and Installation” in
Section 1I (Page 1I-8).

20
21

19

22
27

26
IFL311140091-03

15) On the remote control model; IFL311140092-03

Remove the bolt, clutch control lever (23) and 18) Disconnect the neutral switch lead wire connector
throttle control lever (24). (28), engine stop switch lead wire connector (29)
and caution lamp lead wire connector (30).
Cut the cable tie securing neutral switch lead wire.

30
24

23 29
28
IFL311140235-02

16) On the remote control model;

Remove the bolts and remote control cable holder IFL311140093-02

(25). 19) Loosen the clutch rod lock nut (31).

To separate the clutch rod from shift rod, unscrew
the connector (32).

25

32
31

IFL311140236-02

IFL311140094-03
1D-19 Power Unit Mechanical:

20) On the tiller handle model; 24) Lift up and remove the clutch shaft holder (with
Remove the bolts (33) securing steering bracket. clutch rod and clutch shaft).

33
IFL311140095-02 IFL311140099-02

21) Remove the bolt (34) securing front panel. 25) Disconnect the ignition coil lead wire connectors.
Remove the bolts securing ignition coils (37).
Remove all ignition coil and spark plugs.

37

34

IFL311140096-02

22) Slide front panel (35) away from clutch shaft holder.
IFL311140100-02

26) Disconnect CMP sensor connector at sensor.

Remove the bolt and CMP sensor (38).

35

IFL311140097-02
38
23) Remove the bolts securing clutch shaft holder (36).

IFL311140101-02

36

IFL311140098-02
 Power Unit Mechanical: 1D-20

27) Remove the bolts, rectifier/ regulator No.1 (39), No2 30) Disconnect CKP sensor lead wire connector (44)
(40) and bracket. and cylinder temp. sensor lead wire connector (45).
Refer to “Rectifier / Regulator Removal and
Installation” in Section 1K (Page 1K-7).

39 40 44 45

IFL311140105-02

31) Remove the bolt and cam pulley cover (46).

IFL311140102-03

28) Loosen screw and disconnect blue/yellow lead wire

(41) from oil pressure switch (42).

46

42
41

IFL311140106-02

32) Loosen and remove the cylinder temp. sensor (47).

IFL311140103-02

29) Disconnect lead wire connector from ECM (43), then

remove ECM.

43
47

IFL311140107-02

33) Remove the screws and CKP sensor (48).

IFL311140104-02

48

IFL311140108-02
1D-21 Power Unit Mechanical:

34) Remove the flywheel (49). 37) Remove the three bolts securing electric parts holder
Refer to “Flywheel Removal and Installation” in (52).
Section 1K (Page 1K-4). Remove the electric parts holder (with main
harness).
Special tool
(A): 09930–48720 (Flywheel holder)
(B): 09930–49211 (Flywheel holder
attachment)
(C): 09930–39411 (Flywheel remover)
(D): 09930–39420 (Flywheel remover bolts)
52
(A)

IFL311140112-02

38) Remove the bolt and PORT side cover holder (53).
(C)
(B) (D)
49
IFL311140109-03
53
35) Remove the bolts securing battery charge coil (50).
Cut the cable tie securing battery charge coil lead
wire to electric parts holder.
Remove the battery charge coil.

50
IFL311140113-02

39) Remove the ten bolts and exhaust manifold (54).

IFL311140110-02
54
36) Remove the two harness clamps (51) from side
cover holder by releasing clamps’ lock.

51 IFL311140114-02

IFL311140111-02
 Power Unit Mechanical: 1D-22

40) Remove the cylinder head cover (55). 43) Remove the camshaft pulley (59) and crankshaft
Refer to “Cylinder Head Cover Removal and timing pulley (60).
Installation” (Page 1D-3). Refer to “Camshaft Pulley / Crankshaft Timing Pulley
/ Timing Belt Removal and Installation” (Page 1D-
11).

55

59
IFL311140115-02 60
41) Loosen all valve adjusting lock nuts (56).
Loosen the six valve adjusting screws (57) fully. IFL311140118-02

Leave the screws in place. 44) Remove the ten bolts (61).
Lift up and remove power unit from engine holder.
56 57

56

57

61

IFL311140116-03
IFL311140119-02
NOTICE
After the timing belt has been removed,
independently turning cam pulley or
crankshaft will cause interference between
piston and valve, which cause damage to
these related parts.

To prevent valve damage, loosen valve

61
adjusting screws fully before removing
timing belt.

42) Remove the timing belt (58).

IFL311140120-02

58

IFL311140117-02
1D-23 Power Unit Mechanical:

Installation • Install seal (3).

Installation is reverse order of removal with special
attention to the following step.

NOTICE
Previously used gasket may leak oil and/or
cooling water, resulting in engine damage.

Do not reuse gasket. Always replace with

new part. 3

Power unit

NOTE IFL311140123-02

Before installing power unit, apply sealant to • Lower the power unit onto engine holder.
the two hatched areas shown in the NOTE
illustration.
Rotate crankshaft to aid alignment of
: Sealant 99000–31140 (SUZUKI Bond 1207B driveshaft and crankshaft splines.
(100 g))
• Apply Suzuki silicone seal to power unit mounting
bolts and tighten bolts to specified torque.
: Sealant 93691–80030 (SUZUKI Silicone
Seal (100 g))
Tightening torque
Power unit mounting bolt (a): 23 N·m (2.3 kgf-m,
16.5 lbf-ft)

IFL311140121-04 (a)

• Install dowel pins (1), gasket (2).

Apply water resistant grease to driveshaft splines.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))

1
IFL311140124-03
2

(a)

1
IFL311140122-02

IFL311140125-03
 Power Unit Mechanical: 1D-24

Camshaft pulley / crankshaft timing pulley / timing Exhaust manifold

belt • Assemble gasket (1) and exhaust manifold (2) to
• Install the camshaft pulley (1) and crankshaft timing cylinder head block and engine holder, then secure
pulley (2). with bolts.
• Install timing belt (3). Tightening torque
Refer to “Camshaft Pulley / Crankshaft Timing Pulley / Exhaust manifold bolt (a): 23 N·m (2.3 kgf-m, 16.5
Timing Belt Removal and Installation” (Page 1D-11). lbf-ft)

2
1
2

IFL311140126-02
IFL311140129-02

(a)

3 2

IFL311140127-03
IFL311140130-02

Cylinder head cover Electric parts holder

NOTE • Install the electric parts holder (1), then tighten it with
bolts.
Before installing cylinder head cover, check
Tighten the harness GND lead wire with bolt “A”.
valve clearance.
Refer to “Valve Clearance Inspection and
Adjustment” in Section 0B (Page 0B-8).
1
• Install the cylinder head cover (1).
Refer to “Cylinder Head Cover Removal and
Installation” (Page 1D-3).

“A”
IFL311140131-02
1

IFL311140128-02
1D-25 Power Unit Mechanical:

Flywheel • Install the CKP sensor (3).

• Install the stator (battery charge coil) (1). Refer to “CKP Sensor Removal and Installation” in
Refer to “Battery Charge Coil Removal and Section 1C (Page 1C-7).
Installation” in Section 1K (Page 1K-5).

1 3

IFL311140135-02

IFL311140132-02
Rectifier/Regulator
• Secure the battery charge coil lead wire to the electric
Install the rectifier/regulator No.1 (1), No.2 (2), and
parts holder with cable tie.
bracket.
Refer to “Rectifier / Regulator Removal and Installation”
in Section 1K (Page 1K-7).

2
1

IFL311140133-02

• Install flywheel (2) and tighten flywheel nut to

specified torque. IFL311140136-02
Refer to “Flywheel Removal and Installation” in
Section 1K (Page 1K-4). Clutch shaft holder
Tightening torque Install the clutch shaft holder (1), then tighten it with
Flywheel nut (a): 100 N·m (10.0 kgf-m, 72.5 lbf-ft) bolts.

Special tool
(A): 09930–48720 (Flywheel holder)
(B): 09930–49211 (Flywheel holder
attachment)

(A)
1

(a)

IFL311140137-02

(B)

2
IFL311140134-02
 Power Unit Mechanical: 1D-26

Starter motor Camshaft, Rocker Arm and Rocker Arm Shaft

• Install the starter motor (1). Removal and Installation
CENFL3121406012
Refer to “Starter Motor Removal and Installation” in
Removal
Section 1I (Page 1I-8).
1) Remove the power unit.
Refer to “Power Unit Removal and Installation”
(Page 1D-15).
2) Remove the oil pump (1).
Refer to “Oil Pump Removal and Installation” in
Section 1E (Page 1E-2).

IFL311140138-02
1
Intake manifold
• Install the air intake silencer case, throttle body and
intake manifold (1).
Refer to “Intake Manifold Removal and Installation”
(Page 1D-6). IFL311140140-02

3) Remove the two bolts (2) securing rocker arm shaft,

then remove the rocker arm shafts (3).
1 NOTE
Install the 10 mm bolt into the lower end of
rocker arm shaft and pull the rocker arm
shaft out.

IFL311140139-02 3

Final assembly check

• Perform the following final assembly checks to ensure
proper and safe operation of the repaired unit. 3

– All parts removed have been returned to their

original positions.
2
– Lower unit gear engagement is properly adjusted. IFL311140141-02

– Fuel and water hose routing matches service

manual illustration.
Refer to “Fuel/Water Hose Routing” in Section 4B
(Page 4B-1).
– Wire routing matches service manual illustration.
Refer to “Wiring Harness Routing Diagram” in 3
Section 4A (Page 4A-7).
– No fuel leakage is evident when fuel system is
pressurized.
Refer to “Fuel Leakage Check Procedure” in
Section 1G (Page 1G-15).
– No water leakage is evident during final test IFL311140143-02

running.
1D-27 Power Unit Mechanical:

NOTE 6) Remove the camshaft oil seal (8).

• Both intake rocker arm shaft and the Special tool
exhaust rocker arm shaft are the same, (A): 09913–50121 (Oil seal remover)
however there are directions for them on
their assembling.
The securing bolts for rocker arm shafts (A)

cannot be tightened if directions of them

are not right.
For ease of assembling, pay attention to
position and direction of each rocker arm 8
shafts when removing them.
• Reassemble each rocker arm shaft to its
original position.

4) Remove the all rocker arm retainers (4), rocker arms IFL311140145-02
(5) and wave washers (6).
Installation
NOTE
1) Install the oil seal (1) with the spring / lipped side
Note the position of wave washers before facing inward. Apply engine oil to oil seal lip.
removing them.
The wave washers are used only on the NOTICE
intake rocker arm side but not the exhaust Removing the oil seal can cause damage to
one. the seal lips, causing oil to leak.

Do not reuse the seal once removed.

5 4 Always install a new oil seal.

6
IFL311140142-02
1
5) Remove the camshaft (7) pulling toward oil pan side.

NOTE
IFL311140146-02
Pull out camshaft toward oil pan side. 2) Apply engine oil to the surface of each camshaft lobe
and journals.
3) Install the camshaft (2) from oil pan side.

IFL311140144-02

IFL311140147-02
 Power Unit Mechanical: 1D-28

4) Apply engine oil to rocker arms. 6) Tighten rocker arm shaft bolts (7) securely.
Install the rocker arm retainers (3), rocker arms (4),
wave washers (5). NOTE
The bolt hole on rocker arm shaft has been
NOTE offset from the shaft center.
Reassemble each rocker arm to its original If the rocker arm shaft bolt cannot be
position. tightened smoothly by hand, turn the rocker
arm shaft at 180°. Then the bolt will be able to
NOTE tighten.
The installation of the wave washer is only on
Tightening torque
the intake rocker arm side.
Rocker arm shaft bolt (a): 6 N·m (0.6 kgf-m, 4.3
lbf-ft)

5
7 (a)
IFL311140148-03
IFL311140150-02
5) Apply engine oil to the rocker arm shafts (6).
Install the rocker arm shafts. 7) Install the oil pump.
Refer to “Oil Pump Removal and Installation” in
NOTE Section 1E (Page 1E-2).
• Reassemble each rocker arm shaft to its 8) Install the power unit.
original position. Refer to “Power Unit Removal and Installation”
(Page 1D-15).
• Both intake rocker arm shaft and the
exhaust rocker arm shaft are the same,
however there are directions for them on
their assembling.
The securing bolts for rocker arm shafts
cannot be tightened if directions of them
are not right.

IFL311140149-02
1D-29 Power Unit Mechanical:

Camshaft, Rocker Arm and Rocker Arm Shaft Decompression Parts

Inspection Inspect the decompression parts on the camshaft.
CENFL3121406013 If abnormal movement is found, replace the camshaft.
NOTE
If any component is worn excessively,
cracked, defective or damaged in any way, it
must be replaced.

Cam Face
Inspect cam face for scratches and wear.
If any of the above conditions are found, replace
camshaft.

Cam Wear
Using micrometer, measure cam height.
IFL311140153-03
If measurement exceeds service limit, replace camshaft.
Cam height “a” Camshaft Journal Oil Clearance
Standard Service limit Using a micrometer, small bore gauge and dial calipers,
25.430 – 25.490 mm 25.330 mm measure the journal diameters (O.D.) in two directions at
IN. two places, and journal bore diameters (I.D).
(1.0012 – 1.0035 in.) (0.9972 in.)
25.140 – 25.200 mm 25.040 mm Subtract the journal diameter measurement from the
EX. journal bore measurement to determine the journal oil
(0.9898 – 0.9921 in.) (0.9858 in.)
clearance.
If the journal oil clearance exceeds the service limit,
replace camshaft and if necessary, cylinder head and/or
oil gallery block.
Special tool
(A): 09900–20205 (Micrometer (0 – 25 mm))
(B): 09900–20202 (Micrometer (25 – 50 mm))
(C): 09900–20605 (Dial calipers (10 – 34 mm))
Camshaft journal oil clearance
Standard (Top, Lower): 0.020 – 0.062 mm (0.0008 –
“a”
0.0024 in.)
Standard (Center): 0.025 – 0.075 mm (0.0010 – 0.0030
IFL311140151-02
in.)
Service limit (Top, Lower): 0.100 mm (0.0039 in.)
Camshaft Runout
Service limit (Center): 0.100 mm (0.0039 in.)
Support camshaft on a surface plate using a set of V-
blocks. Camshaft journal inside diameter
Measure runout using a dial gauge. Standard (Top): 27.000 – 27.021 mm (1.0630 – 1.0638
If measurement exceeds service limit, replace camshaft. in.)
Standard (Center): 34.500 – 34.525 mm (1.3583 –
Special tool
1.3593 in.)
(A): 09900–20606 (Dial gauge)
Standard (Lower): 23.000 – 23.021 mm (0.9055 –
(B): 09900–20701 (Magnetic stand)
0.9063 in.)
Camshaft runout
Camshaft journal outside diameter
Service limit: 0.10 mm (0.004 in.)
Standard (Top): 26.959 – 26.980 mm (1.0614 – 1.0622
in.)
Standard (Center): 34.450 – 34.475 mm (1.3563 –
(B) 1.3573 in.)
(A)
Standard (Lower): 22.959 – 22.980 mm (0.9039 –
0.9047 in.)

IFL311140152-03
 Power Unit Mechanical: 1D-30

Rocker arm shaft to rocker arm clearance

Standard: 0.013 – 0.039 mm (0.0005 – 0.0015 in.)
(A) (B)
Service limit: 0.060 mm (0.0024 in.)
Rocker arm shaft outer diameter
Standard: 11.979 – 11.990 mm (0.4716 – 0.4720 in.)
Rocker arm inside diameter
Standard: 12.003 – 12.018 mm (0.4726 – 0.4731 in.)

(B)

IFL311140154-02

(C)

IFL311140157-02

(A)

IFL311140155-02

Rocker Arm and Adjusting Screw

Inspect the rocker arm and adjusting screw.
• If the tip of adjusting screw shows excessive wear,
replace the screw.
• The arm must be replaced if its cam-riding roller is
badly worn. IAJ311140018-01

Rocker Arm Shaft Runout

Using a set of V-blocks, support the rocker arm shaft on
a surface plate. Measure runout using a dial gauge.
If measurement exceeds service limit, replace rocker
arm shaft.
Special tool
(A): 09900–20602 (Dial gauge)
(B): 09900–20701 (Magnetic stand)
(C): 09900–21304 (Steel “V” block set)
Rocker arm shaft runout
IFL311140156-02
Service limit: 0.120 mm (0.005 in.)
Rocker Arm Shaft to Rocker Arm Clearance
Using a micrometer and bore gauge, measure rocker
arm shaft outside diameter and rocker arm inside
diameter. The difference between the two readings is the
rocker arm to arm shaft clearance. If measurement (A)
exceeds service limit, replace shaft or arm, or both. (B)

Special tool
(A): 09900–20205 (Micrometer (0 – 25 mm))
(B): 09900–20605 (Dial calipers (10 – 34 mm))
(C)

IFL311140158-03
1D-31 Power Unit Mechanical:

Cylinder Head Assembly Components

CENFL3121406014

9 (a)

7 8
7
6
6

5
5
4 4

IFL311140016-02

1. Intake valve 4. Valve spring seat 7. Valve spring retainer : 30 N⋅m (3.0 kgf-m, 22.0 lbf-ft)
2. Exhaust valve 5. Valve stem seal 8. Valve cotter : Apply engine oil.

3. Valve guide 6. Valve spring 9. Cylinder head bolt

 Power Unit Mechanical: 1D-32

Cylinder Head Removal and Installation 1) Insert the dowel pins (1) and place a new cylinder
CENFL3121406015 head gasket (2) into position on the cylinder.
Removal
1) Prior to removing cylinder head assembly;
• Remove the power unit. 1
1
Refer to “Power Unit Removal and Installation”
(Page 1D-15).
• Remove the camshaft.
Refer to “Camshaft, Rocker Arm and Rocker Arm
Shaft Removal and Installation” (Page 1D-26).
2) Loosen and remove eight cylinder head bolts in the 2
order indicated in figure.
Remove cylinder head assembly and head gasket.
IFL311140161-02
NOTE 2) Position cylinder head on cylinder.
Use special tool (8 mm deep socket wrench)
when loosening cylinder head bolts. NOTE
Use special tool (8 mm deep socket wrench)
Special tool when tightening cylinder head bolts.
(A): 09919–19910 (Deep socket wrench
(8mm)) Special tool
(A): 09919–19910 (Deep socket wrench
(8mm))
“4” “5” “7” “2” 3) Apply engine oil to cylinder head bolts.
4) Lightly seat all cylinder head bolts at first.
According to tightening order in figure, tighten bolts
to 1/2 of specified torque, and finally to full specified
torque.
“1” “8” “6” “3” Tightening torque
Cylinder head bolt (1st step) (a): 15 N·m (1.5 kgf-
m, 11 lbf-ft)
IFL311140159-03 Cylinder head bolt (Final step) (a): 30 N·m (3.0
kgf-m, 22.0 lbf-ft)

(A)
“5” “4” “2” “7”

“8” “1” “3” “6”

IFL311140160-02
IFL311140162-03

Installation
Installation is in reverse order of removal paying special
attention to the following steps.

NOTICE
(a)
A previously-used gasket may leak
combustion gas and/or cooling water,
resulting in engine damage.

Do not re-use gasket once removed.

Always use a new gasket.
IFL311140163-03
1D-33 Power Unit Mechanical:

5) Install the camshaft and rocker arms. 2) Remove valve spring retainer (2), valve spring (3)
Refer to “Camshaft, Rocker Arm and Rocker Arm and valve (4).
Shaft Removal and Installation” (Page 1D-26).
1 2 3 5 6 4
Cylinder Head Disassembly and Assembly
CENFL3121406016
Disassembly
1) Using valve lifter and attachment, remove valve
1
cotters (1) while compressing valve spring. I9J011140210-01

Special tool 3) Remove valve stem seal (5) and valve spring seat
(A): 09916–14510 (Valve lifter) (6).
(B): 09916–14521 (Valve lifter attachment)
NOTE
(C): 09916–84511 (Tweezers)
Reassemble each valve and valve spring in
their original positions.
(A)

(B)

IFL311140164-02

6
(C)
IFL311140165-02

(A)
Assembly
(B) Reassemble in reverse order of disassembly paying
special attention to the following steps.

6
5

2
4

1 1
I9J011140209-01

3
I9J011140212-03
 Power Unit Mechanical: 1D-34

1) Install valve spring seat (1) to cylinder head. 5) Install valve spring (4), and valve retainer (5).
2) After applying engine oil to stem seal (2), then install
NOTE
valve stem seal onto valve guide by pushing with
finger tip. Set valve spring in place with narrow spiral
area facing valve seat.
NOTICE
Removing the stem seal can be damaged,
causing oil to get down past the seal. “C”

“A”
Do not reuse stem seal once removed.
Always install new seal.

“B”
2

“D”
I9J011140035-01

“A”: Large-pitch “C”: Valve spring retainer side

“B”: Small-pitch “D”: Valve spring seat side
1

IFL311140166-02 6) Hold valve spring compressed with special tool and

3) Apply engine oil to stem seal, valve guide bore and install valve cotters (6).
valve stem. Make sure valve cotters are properly seated in
groove “A”.
4) Install valve (3) to valve guide.
Special tool
NOTE (A): 09916–14510 (Valve lifter)
Reassemble each valve and valve spring to (B): 09916–14521 (Valve lifter attachment)
their original position. (C): 09916–84511 (Tweezers)

(A)

(B)

IFL311140167-02
I9J011140034-01

(C)
(A)

(B)
6

6
“A”
IFL311140168-02
1D-35 Power Unit Mechanical:

Cylinder Head Components Inspection and • Check water jackets. If clogged or obstructed, clean
Servicing water jackets.
CENFL3121406017
NOTE
If cracks, excessive wear or other damage is
found on any component, replace
component.

Cylinder Head
• Remove all carbon from combustion chambers.

NOTE
• Do not use any sharp edged tool to scrape
carbon off cylinder head or its IFL311140172-02
components.
• Be careful not to scuff or nick metal Cylinder head distortion
surfaces when decarbonizing. NOTE
Distorted mating surface of cylinder head
and cylinder head gasket causes combustion
gas and/or cooling water to leak, which may
result in overheating and reduced power
output.

• Using a straightedge and thickness gauge, measure

cylinder head distortion (gasket surface) at a total of
six locations as shown.
If measurement exceeds service limit, resurface or
replace cylinder head.

IFL311140170-02 Special tool

• Check cylinder head for cracks in intake and exhaust (A): 09900–20803 (Thickness gauge)
ports, combustion chambers, and head surface. Cylinder head distortion
If cracks or other damage is found, replace cylinder Service limit: 0.06 mm (0.002 in.)
head.
• Check valve seat, if cracks or other damage is found,
replace cylinder head.

IFL311140173-03

IFL311140171-02

(A)

IFL311140174-02
 Power Unit Mechanical: 1D-36

NOTE Valve guide inside diameter

Cylinder head can be resurfaced, using a Using a small bore gauge, measure valve guide inside
surface plate and #400 grit wet sandpaper. diameter.
Valve guide inside diameter
Valve and Valve Guide Standard (IN., EX.): 5.000 – 5.012 mm (0.1969 –
Valve guide to valve stem clearance 0.1973 in.)
Using a micrometer and bore gauge, take diameter
readings on valve stems and guides to check guide to
stem clearance.
Be sure to take readings at more than one place along
the length of each stem and guide.
If measurement exceeds service limit, replace valve and/
or valve guide. Refer to “Valve guide replacement” (Page
1D-39).
Special tool
(A): 09900–20205 (Micrometer (0 – 25 mm))

I9J011140040-01
Valve stem outside diameter
Using micrometer, measure valve stem outside Valve guide to valve stem clearance
diameter. Standard (IN.): 0.010 – 0.037 mm (0.0004 – 0.0015 in.)
Standard (EX.): 0.030 – 0.057 mm (0.0012 – 0.0022
Valve stem outside diameter
in.)
Standard (IN.): 4.975 – 4.990 mm (0.1959 – 0.1965 in.)
Service limit (IN.): 0.070 mm (0.0028 in.)
Standard (EX.): 4.955 – 4.970 mm (0.1950 – 0.1957
Service limit (EX.): 0.090 mm (0.0035 in.)
in.)
Valve stem deflection
If unable to measure valve guide inside diameter, check
“Valve stem deflection”.
If measurement exceeds service limit, replace valve.
If measurement still exceeds service limit with new
valve, replace valve guide.
Measure valve stem deflection as follows;
1) Install valve into valve guide.
2) Position valve head at approx. 5 mm (0.20 in.) away
(A)
from valve seat.
I9J011140039-02
3) Move valve head in the direction “a” – “b”, and
measure deflection.
Special tool
(A): 09900–20606 (Dial gauge)
(B): 09900–20701 (Magnetic stand)
Valve stem deflection
Service limit (IN.): 0.14 mm (0.006 in.)
Service limit (EX.): 0.18 mm (0.007 in.)

(A)

“a”

“b”

(B)
IFL311140169-05
1D-37 Power Unit Mechanical:

Valve stem end Valve head radial runout

Inspect valve stem end face for pitting and wear. Measure valve head radial runout.
If pitting or wear is found, valve stem end may be To measure runout, rotate valve slowly.
resurfaced. If measurement exceeds service limit, replace valve.
Use caution when resurfacing, do not grind away stem
Special tool
end chamfer.
(A): 09900–20606 (Dial gauge)
When chamfer has been worn away, replace valve.
(B): 09900–21304 (Steel “V” block set)
: 09900–20701 (Magnetic stand)
Valve head radial runout
Service limit (IN., EX.): 0.08 mm (0.003 in.)

(A)

I9J011140041-01

Valve stem runout

(B)
Measure valve stem runout.
I9J011140043-03
If measurement exceeds service limit, replace valve.
Special tool Valve head thickness
(A): 09900–20606 (Dial gauge) Measure thickness “a” of valve head.
(B): 09900–20701 (Magnetic stand) If measurement exceeds service limit, replace valve.
(C): 09900–21304 (Steel “V” block set)
Special tool
Valve stem runout : 09900–20101 (Vernier calipers (150 mm))
Service limit (IN., EX.): 0.05 mm (0.002 in.)
Valve head thickness
Service limit (IN., EX.): 0.5 mm (0.02 in.)

(A)

(B)
(C)

I9J011140042-02 “a”
45°
I9J011140044-01
 Power Unit Mechanical: 1D-38

Valve seat contact width Valve seat servicing

Measure valve seat contact width as follows: If valve seat contact width is out of specification, reface
1) Remove all carbon from valve and seat. valve seat as follows:
2) Coat valve seat evenly with Prussian blue (or Valve seat angle
equivalent). Intake side: 15° / 45°
3) Install valve into valve guide. Exhaust side: 15° / 45°
4) Put valve lapper on valve.
IN. EX.
.
Special tool
(A): 09916–10911 (Valve lapper)

(A) 45° 45°

15° 15°
IFL311140013-02

To reface a valve seat, use the following valve seat

cutting tool.
• Valve seat cutter 45° (Neway 268)
• Valve seat cutter 15° (Neway 243)
• Valve seat cutter 45° (Neway 122)
• Valve seat cutter 15° (Neway 121)
IFL311140176-02 • Solid pilot (Neway, N-140-5.0) (09916-22410)
5) Rotate valve while gently tapping valve contact area • Solid pilot (Neway, N-100-5.0) (09916-24311)
against seat.
• Handle (Neway, N-505) (09916-54910)
6) Continue until a pattern is on valve seat face with
prussian blue. NOTE
7) Measure valve seat contact width “a”. Turn cutter clockwise, never
Special tool counterclockwise.
: 09900–20101 (Vernier calipers (150 mm))
1) Remove all carbon from valve and valve seat.
Valve seat contact width “a” 2) Using 45° angle cutter, reface valve seat.
Standard (IN., EX.): 0.9 – 1.1 mm (0.035 – 0.043
3) Check valve seat contact width “a”.
in.)
Refer to “Valve seat contact width” (Page 1D-38).
If measurement exceeds specification, repair valve Too high (wide)
seat.
Refer to “Valve seat servicing” (Page 1D-38).

“a”

“a” I9J011140047-01

Too low (narrow)

IFL311140002-02

“a”

I9J011140048-01
1D-39 Power Unit Mechanical:

• If width “a” is too high (or wide), reface valve seat Valve guide replacement
using small angle cutter.
NOTE
• If width “a” is too low (or narrow), reface valve seat
using 45° angle cutter. Be careful not to damage cylinder head when
replacing valve guide.

1) Using valve guide remover, drive valve guide out

from combustion chamber side towards valve spring
side.

NOTE
Do not reuse valve guide once it has been
removed.
Always use a new valve guide (oversize)
when assembling.

IFL311140177-02 Special tool

4) Clean up any burrs using 45° angle cutter very (A): 09916–44310 (Valve guide remover)
lightly.
5) Lap valve on seat in two steps, first with coarse grit
lapping compound applied to face and the second
(A)
with fine grit compound.
6) Recheck valve seat contact width “a”.

NOTE
Clean and assemble cylinder head and valve
components.
Fill intake and exhaust ports with solvent to
check for leaks between valve seat and valve.
If any leaks occur, inspect valve seat and IFL311140179-02

face for burrs or other things that could 2) Ream valve guide hole with ø 10.5 mm reamer to
prevent valve from sealing. true hole and remove burrs.

NOTICE
Improper handling of the reamer will cause
damage to the valve guide hole.

When refinishing or removing the reamer

from the valve guide hole, always turn it
clockwise.

Special tool
(B): 09916–37320 (Valve guide reamer (ø
10.5 mm))
IFL311140178-04
(C): 09916–34542 (Valve guide reamer
handle)

(C)
(B)

IFL311140180-02
 Power Unit Mechanical: 1D-40

3) Drive valve guide in from valve spring side to the

specified height.
Measure valve guide protrusion “a”.
Special tool
(A): 09916–44310 (Valve guide remover)
: 09900–20101 (Vernier calipers (150 mm))
Valve guide protrusion “a” (A)
Standard (IN., EX.): 10.6 – 11.0 mm (0.42 – 0.43 I9J011140054-02
in.)
Valve spring preload
Measure valve spring preload.
“a” If lower than service limit, replace valve spring.
Special tool
: 09900–20101 (Vernier calipers (150 mm))
(A)
Valve spring preload
Standard (IN., EX.): 85 – 94 N (8.5 – 9.4 kg, 18.8 – 20.8
lbs.) at 28.5 mm (1.12 in.)
Service limit (IN., EX.): 75 N (7.5 kg, 16.5 lbs.) at 28.5
mm (1.12 in.)
IFL311140181-02

4) Ream valve guide bore with ø 5.0 mm reamer.

NOTE
Clean and oil valve guide bore after reaming.

Special tool
(D): 09916–34570 (Valve guide reamer (ø 5.0
mm))
(C): 09916–34542 (Valve guide reamer
I9J011140055-01
handle)
Valve spring squareness
Use a square and surface plate to check each spring for
(D)
(C)
squareness (clearance between end of valve spring and
square).
If measurement exceeds service limit, replace valve
spring.
Special tool
: 09900–20101 (Vernier calipers (150 mm))
Valve spring squareness “a”
Service limit (IN., EX.): 1.5 mm (0.06 in.)
IFL311140182-02

“a”
Valve spring free length
Check spring strength by measuring free length.
If lower than service limit, replace valve spring.
Special tool
(A): 09900–20101 (Vernier calipers (150 mm))
Valve spring free length
Standard (IN., EX.): 34.29 mm (1.350 in.)
Service limit (IN., EX.): 32.92 mm (1.296 in.)
I9J011140056-02
1D-41 Power Unit Mechanical:

Pistons, Piston Rings, Connecting Rods, Cylinder and Crankshaft Components

CENFL3121406018

15 (b)

16 (c)

14

13
13
12 7
11 8 (a)

10

12 9

6
4

5
5

IFL311140015-05

1. Cylinder block 6. Conrod 11. Crankshaft 16. Bolt (6 mm)

2. Piston ring set 7. Conrod cap 12. Crankshaft main bearing : 10 N⋅m (1.0 kgf-m, 7.2 lbf-ft)
3. Piston 8. Conrod cap bolt 13. Dowel pin : 28 N⋅m (2.8 kgf-m, 20.0 lbf-ft)
4. Piston pin 9. Oil seal 14. Crankcase : 11 N⋅m (1.1 kgf-m, 8.0 lbf-ft)
5. Circlip 10. Oil seal 15. Bolt (8 mm) : Apply engine oil.
 Power Unit Mechanical: 1D-42

Pistons, Piston Rings, Connecting Rods, 5) Remove the oil relief valve (5).
Cylinder and Crankshaft Disassembly and
Assembly
CENFL3121406019
Disassembly
1) Before performing service work in this section:
• Remove power unit.
Refer to “Power Unit Removal and Installation”
(Page 1D-15).
• Remove cylinder head.
Refer to “Cylinder Head Removal and Installation” 5
(Page 1D-32).
2) Remove oil pressure switch (1). IFL311140186-03

6) Remove eight bolts (6).

Remove eight bolts (7).
Remove crankcase (8) from cylinder block.

8 6

1 7

IFL311140183-02

3) Remove the oil filter (2).

6
Special tool IFL311140187-03
(A): 09915–47341 (Oil filter wrench)
NOTE
For proper assembly, mark cylinder number
2 on all pistons, conrods, and conrod caps,
using quick drying paint.

1
2
(A)

IFL311140184-03 3
4) Remove the thermostat cover (3) and thermostat (4).
Refer to “Thermostat Removal and Installation” in
Section 1F (Page 1F-3).

IFL311140188-02

3 4

IFL311140185-03
1D-43 Power Unit Mechanical:

7) Remove all conrod cap bolts (9) and conrod caps 10) Remove two compression rings (top and 2nd) and oil
(10). ring from piston. Mark cylinder number on conrod
using quick dry paint.

10

IFL311140189-03

8) Remove crankshaft (11). IDK111140141-01

Remove oil seals (12) from crankshaft. 11) Remove piston pin circlips (13) as shown.

13
11

12

12
IFL311140004-04

12) Remove piston pin from conrod.

IFL311140190-03

9) Mark cylinder number on pistons using quick dry NOTE

paint. Reassemble each piston, piston pin and
Push piston (with conrod) out through the top of conrod in their original combination and
cylinder bore. position.
NOTE
• To prevent damage to piston rings,
decarbon top of cylinder bore wall before
removing piston.
• Reassemble each conrod cap to its
original position after removing piston
from bore.

I9J011140058-01
1
2
3

IFL311140191-02
 Power Unit Mechanical: 1D-44

Assembly
Assembly is reverse order of disassembly paying special 3
attention to the following steps. 4

NOTICE
If any of the parts is reinstalled into a position
different from the original position, engine 1
problems could occur. 4

If original components are not replaced, each

piston, piston pin and conrod is to be 2
assembled and installed in its original order
and position. IAJ311140004-01

Piston to conrod Piston ring to piston

• Apply engine oil to piston pin (1), piston pin bore and 1) Install the oil ring.
conrod (2).
• Apply engine oil to piston rings.
• Assemble conrod (2) to piston (3) as shown in figure
• Install spacer (1) first, then side rails (2) to piston.
and insert piston pin (1) through piston and conrod.
• Install piston pin circlips (4).
2
NOTE
• Make sure conrod is installed in direction 1
as shown in figure.
• Always use new piston pin circlip.
• Install so that circlip end gap comes within
such range as indicated by arrow.
End gap of the circlip should not be 2
aligned with the cutaway in the piston pin I9J011140011-01
bore.
NOTE
When installing spacer, do not allow spacer
“A”
ends to overlap in groove.

“A”
“B”

“B”

“C”
IFL311140005-03 “B”
“A”: Up mark “C”: Match mark
“B”: Circlip end gap direction
I9J011140012-01

“A”: Incorrect “B”: Correct

1D-45 Power Unit Mechanical:

2) Install the piston rings. Piston to cylinder

• Apply engine oil to piston ring. 1) Apply engine oil to piston and cylinder walls.
• Install 2nd ring (3) and 1st ring (4) to piston. 2) Insert piston and conrod assembly (1) into cylinder
bore from cylinder head side using piston ring
compressor.
“1R” Special tool
(A): 09916–77310 (Piston ring compressor)
“2R” 4
3 NOTE
“C”
Position the up mark “A” on piston head to
flywheel side “B”.

IFL311140006-03

NOTE
• 1st ring (4) and 2nd ring (3) differ in shape (A)
and color as shown in figure.
• As indicated in figure, 1st and 2nd ring are
marked, “1R” or “2R”.
When installing these piston rings, the
marked side “C” of each ring must face
towards top of piston.

IFL311140192-02

4
4
“B”
4

1
“A”

4
3
3
IFL311140007-03

3) Position piston rings so gaps are staggered at

approximately 90 degree angles as shown. IFL311140193-03

“A”: Up mark ( ) “B”: Flywheel side

“G” “H”
Crankshaft to cylinder
Install crankshaft main bearings (1) in cylinder and
“D” crankcase.
Apply engine oil to bearings.

NOTICE
“F” “E”
IFL311140008-02
If the bearing is reinstalled into a position
different from the original position, engine
“D”: Up mark “G”: 2nd ring and oil ring spacer
problems could occur.
“E”: 1st ring “H”: Oil ring upper side rail
“F”: Oil ring lower side rail
If original bearings are not replaced,
assemble each bearing to its original
position.
 Power Unit Mechanical: 1D-46

NOTICE 1) Apply engine oil to oil seal lip.

If oil is present between the bearing’s outside Install upper oil seal (1) and lower oil seal (2) to
surface and crank bearing holder surface, the crankshaft.
bearing could heat up to very high 2) Apply molybdenum oil solution to crank pin and
temperature, resulting in seizure. crankshaft main journal and install crankshaft in
cylinder.
Be sure to thoroughly wipe off any trace of oil
that is present between the bearing’s outside
surface and crank bearing holder surface.
2 1
NOTE
Align bearing tab “A” with notch in cylinder
and crankcase.

IFL311140196-02

NOTE
Before installing crankshaft, apply Suzuki
Bond 1207B to the 4 areas indicating “A” in
the illustration.
Apply Suzuki bond 1207B in 10 mm (0.4 in.)
1 long thin layer on 4 areas.
IFL311140194-02
: Sealant 99000–31140 (SUZUKI Bond
1207B (100 g))
“A” 10 mm (0.4 in.)
“B”
“A”

“A”
1

“B”

IFL311140195-02

“A”: Bearing tab “B”: Oil hole

Crankshaft

NOTE
Replace the oil seal with new one.

NOTE
Install oil seal with its spring / lipped side
facing inward.
“B” “A”

“A” : Apply bond “ ” marked area.

“B” : Do not apply bond “ ” marked area.

IFL311140233-04
1D-47 Power Unit Mechanical:

NOTE Crankcase to cylinder

When installing crankshaft to cylinder, be 1) Clean mating surface of cylinder and crankcase.
sure to fit tab of seal in groove of cylinder. Apply Suzuki bond to mating surface of crankcase
as shown.

NOTE
Apply bond to mating surface only.
Do not allow bond to contact surface of
bearing and groove for the oil seal tab.

NOTE
Apply Suzuki Bond 1207B to the 4 areas
indicating “A” in the illustration in addition to
the sealant normally applied to the crankcase
mating surface.
IFL311140197-02 Apply Suzuki bond 1207B in 10 mm (0.4 in.)
3) Apply engine oil to conrod cap (3). long thin layer on 4 areas.
Install conrod cap (3) to conrod.
: Sealant 99000–31140 (SUZUKI Bond
4) Apply engine oil to conrod cap bolts (4) and tighten
1207B (100 g))
conrod cap bolts in two steps.
Tightening torque “A” “C” 10 mm (0.4 in.)
Conrod cap bolt [1st step] (a): 5 N·m (0.5 kgf-m,
3.5 lbf-ft)
Conrod cap bolt [Final step] (a): 10 N·m (1.0 kgf-
m, 7.2 lbf-ft)
“A”

4 (a)
“B”
3

“B”

“A”

IFL311140198-02

“A”: Match mark

“A”
“A” “C”

“A”, “B” : Apply bond “ ” marked area.

“C” : Do not apply bond “ ” marked area.

IFL311140014-10

4 (a)

IFL311140199-02

5) Pour approx. 2 ml of engine oil to each side surface

of the conrod big end for initial lubrication.
 Power Unit Mechanical: 1D-48

2) Install two dowel pins (1). NOTE

After tightening crankcase bolts, check to be
sure that crankshaft rotates smoothly when
turned by hand.
1
1

IFL311140200-02

3) Install crankcase to cylinder.

Apply engine oil lightly to 8 mm (0.31 in.) crankcase
inside bolts only.
IFL311140202-03
NOTE
Do not apply oil to 6 mm (0.23 in.) crankcase Oil pressure regulator
outside bolts. Install oil pressure regulator (1) to cylinder, then tighten
regulator securely.
NOTE Tightening torque
Tighten 8 mm (0.31 in.) thread diameter bolts Oil pressure regulator (a): 27 N·m (2.7 kgf-m, 19.5
first (following the order shown in figure), lbf-ft)
then tighten 6 mm (0.25 in.) thread diameter
bolts.

4) Tighten crankcase bolts in two steps following the

order indicated below.
Tightening torque
Crankcase (inside) bolt (8 mm) [1st step]: 14
N·m (1.4 kgf-m, 10.0 lbf-ft)
Crankcase (inside) bolt (8 mm) [Final step]: 28
N·m (2.8 kgf-m, 20.0 lbf-ft) 1 (a)
Crankcase (outside) bolt (6 mm) [1st step]: 5
N·m (0.5 kgf-m, 3.6 lbf-ft) IFL311140203-03
Crankcase (outside) bolt (6 mm) [Final step]: 11
N·m (1.1 kgf-m, 8.0 lbf-ft) Engine oil filter
Install the engine oil filter (1).
Refer to “Engine Oil Change and Engine Oil Filter
“16” “12” “10” “14” Replacement” in Section 0B (Page 0B-3).

“5” “1” “4” “8”

1
“6” “2” “3” “7”

“13” “9” “11” “15”

IFL311140201-04

IFL311140204-02
1D-49 Power Unit Mechanical:

Oil pressure switch Cylinder distortion

Install oil pressure switch (1). Service limit: 0.06 mm (0.002 in.)
Refer to “Oil Pressure Switch Removal and Installation”
in Section 1E (Page 1E-5)

IFL311140207-03

IFL311140205-02

Thermostat
Install the thermostat (1) and thermostat cover (2).
Refer to “Thermostat Removal and Installation” in
Section 1F (Page 1F-3).

(A)

IFL311140208-02

NOTE
The cylinder can be resurfaced, using a
1 2 surface plate and #400 grit wet sandpaper.

IFL311140206-02

Cylinder head
Refer to “Cylinder Head Removal and Installation” (Page
1D-32).

Power unit
Refer to “Power Unit Removal and Installation” (Page
1D-15).

Cylinder, Piston and Piston Ring Inspection and IFL311140209-02

Servicing
CENFL3121406020
Water Jackets
NOTE
Check water jackets.
If cracks, excessive wear or other damage is If clogged or obstruction is found, clean water jacket.
found on any component, replace
component.

Cylinder Distortion
Using a straightedge and thickness gauge, measure
cylinder distortion (gasket surface) at a total of six
locations as shown.
If measurement exceeds service limit, resurface or
replace cylinder.
Special tool
(A): 09900–20803 (Thickness gauge)
IFL311140210-02
 Power Unit Mechanical: 1D-50

Cylinder Bore Piston to Cylinder Clearance

Inspect cylinder walls for scratches, roughness, or ridges 1) Measure the piston diameter at a point 9 mm (0.354
which indicate excessive wear. in.) above the piston skirt at a right angle to the
If cylinder bore is very rough, deeply scratched or ridged, piston pin bore.
bore cylinder and use oversize piston.
Special tool
Cylinder Bore Wear (Difference) (A): 09900–20203 (Micrometer (50 – 75
Using telescoping gauge (1), measure cylinder bore in mm))
both axial (vertical line, following crankshaft) and Piston skirt diameter
transverse (horizontal line across crankshaft) directions Standard: 60.365 – 60.380 mm (2.3766 – 2.3772
at two positions as shown in figure. in.)
NOTE
Purchase a commercially available
telescoping gauge for this measurement.
“a”
Check the following:
(A)
• Difference between measurements at the two I9J011140061-02
positions (taper).
“a”: 9 mm (0.354 in.)
• Difference between axial and transverse
measurement (out-of-round). 2) Measure the cylinder bore at 50 mm (1.969 in.)
If measurement exceeds service limit, bore or replace below the cylinder head gasket surface at a right
cylinder. angle to the crankshaft pin.
Cylinder bore wear (difference)
NOTE
Service limit: 0.100 mm (0.0039 in.)
Purchase a commercially available
telescoping gauge (1) for this measurement.
1
Cylinder bore diameter
Standard: 60.400 – 60.415 mm (2.3780 – 2.3785
in.)

1
50 mm
(1.969 in.)
IFL311140211-02

“a”

“b” IFL311140010-02

3) Calculate the piston / cylinder clearance (Clearance

equals difference between piston diameter and
cylinder bore measurements).
If clearance exceeds service limit, replace piston
I9J011140060-01
and/or cylinder or bore cylinder.
Piston to cylinder clearance
Standard: 0.0271 – 0.0425 mm (0.0011 – 0.0017
in.)
Service limit: 0.100 mm (0.0039 in.)
1D-51 Power Unit Mechanical:

Identification of Oversize Piston / Piston Ring Piston

One oversize piston / piston ring components, 0.50 mm Visual inspection
is available. Oversize piston / piston ring are marked as Inspect piston for faults, cracks or other damage.
shown, below. Damaged or faulty piston(s) should be replaced.

Piston Piston ring to groove clearance

Oversize I.D. mark Before checking, piston grooves must be clean, dry and
0.50 mm 50 free of carbon.
Fit piston ring into piston groove, and measure clearance
between ring and ring groove using thickness gauge.
If measurement exceeds service limit, replace piston
and/or piston ring.
Special tool
(A): 09900–20803 (Thickness gauge)
“A”
Piston ring to groove clearance
Standard (1st): 0.030 – 0.070 mm (0.0012 – 0.0028 in.)
Standard (2nd): 0.020 – 0.060 mm (0.0008 – 0.0024
IDK111140012-01 in.)
“A”: I.D. mark: 50 Service limit (1st): 0.12 mm (0.005 in.)
Service limit (2nd): 0.10 mm (0.004 in.)
1st and 2nd piston ring
Oversize I.D. mark
0.50 mm 50
1

1st, 2nd ring

“B”
(A)

I9J011140065-03
I9J011140063-03
1. Piston ring
“B”: I.D. mark

Piston ring groove width

Oil ring Standard (1st): 1.02 – 1.04 mm (0.040 – 0.041 in.)
Oversize I.D. mark Standard (2nd): 1.21 – 1.23 mm (0.048 – 0.048 in.)
0.50 mm One red paint Standard (Oil): 2.01 – 2.03 mm (0.079 – 0.080 in.)

Oil ring spacer Piston ring thickness

Standard (1st): 0.97 – 0.99 mm (0.038 – 0.039 in.)
Standard (2nd): 1.17 – 1.19 mm (0.046 – 0.047 in.)

“C”
I9J011140064-02

“C”: I.D. mark

 Power Unit Mechanical: 1D-52

Piston Ring Piston Pin and Conrod Inspection

CENFL3121406021
Piston ring end gap
Piston Pin
Measure piston ring end gap with piston ring in the
Visual inspection
lowest position of cylinder bore.
If measurement exceeds service limit, replace piston • Check piston pin, conrod small end bore and piston
ring. pin hole for wear or damage.
If badly worn or damaged, replace component.
Special tool
• Apply engine oil on piston pin so that the piston pin
(A): 09900–20803 (Thickness gauge)
can move smoothly in the piston pin hole.
Piston ring end gap If improper condition is found, replace the piston pin
Standard (1st): 0.12 – 0.25 mm (0.0047 – 0.0098 in.) and/or piston.
Standard (2nd): 0.26 – 0.39 mm (0.0102 – 0.0154 in.)
Service limit (1st): 0.70 mm (0.028 in.) Piston pin clearance
Service limit (2nd): 0.70 mm (0.028 in.) Check the piston pin clearance in the conrod small end.
Replace the conrod if its small end is badly worn or
damaged or if clearance exceeds service limit.
(A) Measure the following item:
Special tool
2 (A): 09900–20205 (Micrometer (0 – 25 mm))
(B): 09900–20605 (Dial calipers (10 – 34 mm))
Piston pin outside diameter
Standard: 15.995 – 16.000 mm (0.6297 – 0.6299 in.)
Service limit: 15.980 mm (0.6291 in.)
1
Piston pin hole diameter
IFL311140212-02 Standard: 16.002 – 16.008 mm (0.6300 – 0.6302 in.)
1. Cylinder 2. Piston ring Service limit: 16.030 mm (0.6311 in.)
Conrod small end bore
Piston ring free end gap
Standard: 16.006 – 16.014 mm (0.6302 – 0.6304 in.)
Measure piston ring free end gap using vernier calipers.
If measurement exceeds service limit, replace piston Pin clearance in piston pin hole
ring. Standard: 0.002 – 0.013 mm (0.0001 – 0.0005 in.)
Service limit: 0.050 mm (0.0020 in.)
Special tool
(A): 09900–20101 (Vernier calipers (150 mm)) Pin clearance in conrod small end
Standard: 0.006 – 0.019 mm (0.0002 – 0.0007 in.)
Piston ring free end gap
Service limit: 0.050 mm (0.0020 in.)
Standard (1st): Approx. 6.3 mm (0.2480 in.)
Standard (2nd): Approx. 5.6 mm (0.2205 in.)
Service limit (1st): 5.0 mm (0.1969 in.)
Service limit (2nd): 4.5 mm (0.1772 in.)

(A)
I9J011140068-02

(A)

I9J011140067-02

(B)

I9J011140069-02
1D-53 Power Unit Mechanical:

Crank Pin Diameter

Inspect crank pin for uneven wear or damage.
(B) Measure crank pin for out-of-round “a” – “b” or taper “c” –
“d” with micrometer.
If crank pin is damaged, out-of-round “a” – “b” or taper
“c” – “d” is out of service limit, replace crankshaft.
Special tool
(A): 09900–20202 (Micrometer (25 – 50 mm))
I9J011140070-02
Crank pin diameter
Standard: 28.985 – 29.000 mm (1.1411 – 1.1417 in.)
Crank Pin and Conrod Inspection
CENFL3121406022 Out-of-round and taper
Conrod Big End Side Clearance Service limit: 0.010 mm (0.0004 in.)
Measure conrod big end side clearance with conrod
installed on crank pin as shown.
(A)
If measurement exceeds service limit, replace conrod
and/or crankshaft.
Special tool
(A): 09900–20803 (Thickness gauge)
Conrod big end side clearance
Standard: 0.100 – 0.250 mm (0.0039 – 0.0098 in.)
Service limit: 0.350 mm (0.0138 in.)
Conrod big end width
Standard: 19.950 – 20.000 mm (0.7854 – 0.7874 in.) IFL311140214-02

Crank pin width

Standard: 20.100 – 20.200 mm (0.7913 – 0.7953 in.) Conrod Big End Inside Diameter
Measure the conrod big end inside diameter as follows.
1) Clean the surface of the conrod and the conrod cap.
2) Install the conrod cap to the conrod.
3) Apply the engine oil to the conrod bolts and tighten
the bolts to the specified torque.
Tightening torque
Conrod cap bolt (a): 10 N·m (1.0 kgf-m, 7.2 lbf-ft)
(A)

IFL311140213-02

(a)

IAJ311140010-01
 Power Unit Mechanical: 1D-54

4) Measure the conrod big end inside diameter. 3) Install conrod and conrod cap to crank pin.
Special tool 4) Apply engine oil to conrod cap bolts, then tighten
(A): 09900–20605 (Dial calipers (10 – 34 conrod cap bolts in two steps.
mm)) Tightening torque
Conrod big end inside diameter Conrod cap bolt [1st step] (a): 5 N·m (0.5 kgf-m,
Standard: 29.025 – 29.034 mm (1.1427 – 1.1431 3.5 lbf-ft)
in) Conrod cap bolt [Final step] (a): 10 N·m (1.0 kgf-
m, 7.2 lbf-ft)

(A)

(a)

IAJ311140011-01
IFL311140216-02

Crank Pin / Conrod Big End Oil Clearance NOTE

Check conrod big end oil clearance as follows:
Do not rotate conrod with Plastigauge in
1) Clean surface of conrod, conrod cap and crank pin.
place.
2) Place a piece of Plastigauge on crank pin parallel to
crankshaft. Avoid placing Plastigauge over oil hole. 5) Remove conrod and conrod cap from crank pin.
Special tool 6) Using scale on Plastigauge envelope, measure
(A): 09900–22301 (Plastigauge (0.025 – Plastigauge width at its widest point.
0.076 mm)) If measurement exceeds service limit, replace the
conrod assembly and/or crankshaft.
(A) Conrod big end oil clearance
Standard: 0.025 – 0.049 mm (0.0010 – 0.0019 in.)
Service limit: 0.080 mm (0.0031 in.)

IFL311140215-04

IFL311140217-04

1. Plastigauge 2. Scale
1D-55 Power Unit Mechanical:

Crankshaft Inspection 2) Use a dial gauge to read displacement in axial

CENFL3121406023 (thrust) direction of crankshaft.
Crankshaft Runout If measurement exceeds service limit, replace
Using a dial gauge, measure runout at center journal. crankshaft and/or cylinder assembly.
If measurement exceeds service limit, replace
crankshaft. Crankshaft thrust play
Standard: 0.15 – 0.20 mm (0.006 – 0.009 in.)
Special tool
Service limit: 0.35 mm (0.014 in.)
(A): 09900–20606 (Dial gauge)
(B): 09900–20701 (Magnetic stand)
Crankshaft runout
Service limit: 0.04 mm (0.002 in.)

(A) (B)

IFL311140219-04

Out-of-Round and Taper (Uneven Wear) of Journals

An unevenly worn crankshaft journal shows up as a
IFL311140218-03 difference in diameter at a cross section or along its
length (or both).
Crankshaft Thrust Play This difference, if any, is determined by taking
1) Measure thrust play with crankshaft, journal bearing micrometer readings.
and crankcase/cylinder block assembled in a normal If any journal is badly damaged or if measurements
manner. exceed service limit, replace crankshaft.
Tighten crankcase bolts to specified torque. Special tool
Tightening torque (A): 09900–20202 (Micrometer (25 – 50 mm))
Crankcase (inside) bolt (8 mm) [1st step]: 14 Out-of-round and taper
N·m (1.4 kgf-m, 10.0 lbf-ft) Service limit: 0.01 mm (0.0004 in.)
Crankcase (inside) bolt (8 mm) [Final step]: 28
N·m (2.8 kgf-m, 20.0 lbf-ft) Out-of-round: A – B
Crankcase (outside) bolt (6 mm): 11 N·m (1.1 Taper: a – b
kgf-m, 8.0 lbf-ft) Crankshaft journal outside diameter
Standard: 31.985 – 32.000 mm (1.2592 – 1.2598 in.)

(A)

IFL311140012-03
 Power Unit Mechanical: 1D-56

Crankshaft Main Bearing Inspection

CENFL3121406024
Crankshaft Main Bearing Visual Inspection “A”
Check bearings for pitting, scratches, wear or damage.
If any improper condition is found, replace both upper
and lower halves.
Always replace both bearing halves, never replace only
one half of a bearing set.

“B”

IFL311140221-02

“A”: Bearing tab “B”: Oil hole

3) Install crankshaft to cylinder.

4) Place a piece of Plastigauge across full width of
bearing (parallel to crankshaft) on journal.
Do not place Plastigauge over oil hole.
I9J011140073-01
Special tool
Crankshaft Journal Oil Clearance (A): 09900–22301 (Plastigauge (0.025 –
Check clearance using Plastigauge according to the 0.076 mm))
following procedure.
NOTE
NOTE Do not rotate crankshaft while Plastigauge is
Assemble each bearing in its original installed.
position before checking clearance.

1) Clean surface of bearing holder (crankcase, and

cylinder), bearing, and main bearing journal.
2) Install main bearing (1) to cylinder and crankcase.

NOTE
• Align tab “A” of bearing with notch in
cylinder and crankcase.
• Do not apply engine oil to bearing. (A)

IFL311140222-02

5) Assemble crankcase to cylinder.

6) Apply engine oil lightly to 8 mm (0.31 in.) crankcase
1 inside bolts only.

NOTE
1 Do not apply oil to 6 mm (0.23 in.) crankcase
outside bolts.

NOTE
IFL311140220-02 Tighten 8 mm (0.31 in.) thread diameter bolts
first (following the order shown in figure),
then tighten 6 mm (0.25 in.) thread diameter
bolts.
1D-57 Power Unit Mechanical:

7) Tighten crankcase bolts in two steps following the 8) Remove crankcase from cylinder.
order indicated below. 9) Using scale on Plastigauge envelope, measure
Tightening torque Plastigauge width at its widest point.
Crankcase (inside) bolt (8 mm) [1st step]: 14 Crankshaft journal oil clearance
N·m (1.4 kgf-m, 10.0 lbf-ft) Standard: 0.020 – 0.051 mm (0.0008 – 0.0020 in.)
Crankcase (inside) bolt (8 mm) [Final step]: 28 Service limit: 0.080 mm (0.0031 in.)
N·m (2.8 kgf-m, 20.0 lbf-ft)
Crankcase (outside) bolt (6 mm) [1st step]: 5
3
N·m (0.5 kgf-m, 3.6 lbf-ft)
Crankcase (outside) bolt (6 mm) [Final step]: 11
N·m (1.1 kgf-m, 8.0 lbf-ft)

NOTE
Crankcase must be torqued to specification
in order to assure proper compression of
2
plastigauge and accurate reading of
clearance.
IFL311140223-04

2. Plastigauge 3. Scale

“16” “12” “10” “14”

10) If measurement exceeds service limit, replace
crankshaft main bearing.
“5” “1” “4” “8”
Crankshaft Oil Seal Inspection
CENFL3121406025
“6” “2” “3” “7” Inspect condition. If cracked, cut or damaged, replace.

“13” “9” “11” “15”

IFL311140201-04

IFL311140224-03

IFL311140202-03
 Power Unit Lubrication: 1E-1

Power Unit Lubrication

Power Head

General Description
Engine Lubrication Description
CENFL3121501001
A camshaft driven trochoid type pump provides engine oil to all power unit components requiring lubrication.
Oil from the oil pan is drawn through the oil strainer and passed through a spin-on type oil filter before entering the
main oil gallery.
A pressure regulator (relief valve) is positioned between the oil pump and oil filter to maintain oil pressure at a constant
level.
From the main gallery, oil flow is directed through either drilled internal passages or by splash method to those
surfaces requiring lubrication.

Schematic and Routing Diagram

Engine Oil Lubrication Chart
CENFL3121502001

Crankshaft
Camshaft
main journal #1 Oil jet
upper journal #1

Crank pin #1

Piston M Camshaft EX. rocker IN. rocker

A center journal arm shaft arm shaft
I
N
Crankshaft G
main journal #2 A
L EX. rocker IN. rocker
L arm #1, #2, #3 arm #1, #2, #3
Crank pin #2 E
R
Y
Piston

Oil pressure switch

Crankshaft
main journal #3

Crank pin #3
Oil filter

Piston Oil pressure regulator

Cylinder block

Cylinder head

Camshaft lower journal #3

Oil pump

Engine holder

Oil strainer

Oil pan

IFL311150001-09
1E-2 Power Unit Lubrication:

Diagnostic Information and Procedures

Oil Pressure Check
CENFL3121504001
Refer to “Oil Pressure Check” in Section 0B (Page 0B-22).

Low Oil Pressure Caution System

CENFL3121504002
Refer to “Caution System Description” in Section 1A (Page 1A-9).

Powerhead Lubrication System Diagnosis

CENFL3121504003

Condition Possible cause Correction / Reference Item

Low oil pressure Clogged oil filter. Replace.
Leakage from oil passages. Repair or replace.
Defective oil pump. Replace.
Defective oil pressure regulator. Replace.
Damaged O-ring. Replace.
Combination of above item. Repair or replace.
High oil pressure Using an engine oil of too high viscosity. Replace.
Clogged oil passage. Clean or replace.
Clogged oil pressure regulator. Replace.
Combination of above items. Repair or replace

Service Instructions
Oil Pump Removal and Installation 3) Turn the oil pump shaft (4) until the pin (3) comes out
CENFL3121506001 through hole of oil gallery block (2).
Removal
Remove the oil gallery block.
1) Remove the power unit.
Refer to “Power Unit Removal and Installation” in
Section 1D (Page 1D-15). 2

2) Remove the three bolts (1) securing oil pump, then 4

remove the oil pump and oil gallery block (2).

2
3 3
1

IFL311150007-01

IFL311150006-01
 Power Unit Lubrication: 1E-3

Installation Oil Pump Disassembly and Assembly

Installation is reverse order of removal with special CENFL3121506002

attention to the following steps. Disassembly

• Pour approx. 10 ml (0.4 oz.) of engine oil into pump 1) Remove the screw (1) securing oil pump rotor plate
case for initial lubrication. (2) to the oil pump case, then remove oil pump rotor
plate.
• Apply engine oil to surface of camshaft lower journals.
• Install oil gallery block and oil pump assembly by
aligning the pin “A” on the oil pump shaft with the
recess “B” on the camshaft.
1

2
“B” IFL311150011-01

2) Remove the shaft (3) and pin (4).

IFL311150008-01
3

“A”

IFL311150012-01

3) Take out inner rotor (5) and outer rotor (6).

IFL311150009-01

• Apply thread lock 1342 to oil pump bolts (1) before

threading. 5
• Tighten the oil pump bolts (1) securely.
Tightening torque
Oil Pump bolt (a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
6
1 (a)

IFL311150013-01

IFL311150010-02
1E-4 Power Unit Lubrication:

Assembly Inspection Oil Pump Component Parts

CENFL3121506003
1) Wash, clean and then dry all disassembly parts. NOTE
2) Apply thin coat of engine oil to inner and outer rotors,
If any repair is required on outer rotor, inner
inside surfaces of oil pump case and plate.
rotor and oil pump case / plate, replace them
3) Install outer rotor (1) and inner rotor (2) to pump as an oil pump assembly.
case.
Oil Pump Component Parts
NOTE
Check outer and inner rotors, rotor plate and oil pump
When installing outer rotor, it must be case for excessive wear or damage. Replace as
original in direction of up and down. necessary.

1
IFL311150017-01
IFL311150014-02

4) Assemble the pin (3) to oil pump shaft (4), then Measuring Radial Clearance
install oil pump shaft. Using a feeler gauge, measure radial clearance between
outer rotor and case.
If measurement is not within specifications, replace oil
4 pump assembly.
Radial clearance
3 Service limit: 0.31 mm (0.0122 in.)

IFL311150015-01

5) Install the rotor plate (5), and then tighten screw (6)
securely.
After mounting the rotor plate, make sure that each
rotor turns smoothly by hand.
IFL311150018-01

IFL311150016-01

6) Pour approx. 10 ml (0.4 oz.) of engine oil into pump

case for initial lubrication.
 Power Unit Lubrication: 1E-5

Oil Pressure Switch Removal and Installation Tightening torque

CENFL3121506004 Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5 lbf-
Removal ft)
1) Loosen screw (1) and disconnect blue/yellow lead
wire (2) from oil pressure switch (3).

1
I9J011150002-01

2
1

(a)

IFL311150019-01

2) Remove oil pressure switch from cylinder block.

Installation
Installation is reverse order of removal with special
attention to the following steps.
• Before installing oil pressure switch, wrap screw
threads with sealing tape (1), then tighten switch to IFL311150020-02
specified torque. • Start engine and check oil pressure switch for oil
leakage.
NOTE
Reseal switch if oil leakage is found.
Cut off any excess sealing tape from switch
• Cover the oil pressure switch with the cap (2).
threads before installation.

IFL311150004-01
1E-6 Power Unit Lubrication:

Oil Pressure Switch Inspection Oil Strainer Removal and Installation

CENFL3121506005 CENFL3121506006
NOTE Removal
Before checking the oil pressure switch, Refer to “Engine Holder / Driveshaft Housing / Mounts
make sure the engine oil pressure is within Disassembly” in Section 2A (Page 2A-15).
specification.
Installation
1) Remove the blue/yellow lead wire (1) from oil Refer to “Engine Holder / Driveshaft Housing / Mounts
pressure switch (2). Assembly” in Section 2A (Page 2A-17).

Oil Strainer Related Parts Inspection

CENFL3121506007
2 • Inspect oil strainer. Replace strainer if cracked,
damaged or other abnormal conditions.
If clog or obstruction, clean oil strainer.
• Check condition of O-rings. Replace O-ring if nicked,
cut, worn or other abnormal condition.
1

IFL311150005-01

2) Check the continuity between the switch terminal

and engine body ground.
Special tool
: 09900–25008 (Multi circuit tester set)
Tester knob indication
Continuity ( )
IFL311150021-01
Oil pressure switch continuity
Engine running: Infinity
Engine stopped: Continuity

I9J011150003-01

3) If measurement exceeds specification, replace oil

pressure switch.
4) After testing oil pressure switch, reinstall parts
removed earlier.
 Power Unit Cooling System: 1F-1

Power Unit Cooling System

Power Head

General Description
Water Cooling System Description
CENFL3121601001
The cooling system uses a displacement type flexible vane impeller to supply cooling water to the powerhead
assembly.
To prevent incomplete combustion due to an overcooled engine, and to ensure proper water flow during cold engine
operation, there is a thermostat in the cylinder block.
Motor temperature and cooling system efficiency are monitored by cylinder temp. sensor in the cylinder. If temperature
higher than normal is detected by a sensor, an advance caution of overheat condition is provided.

Displacement Type Water Pump Description

CENFL3121601002
In this displacement type water pump, the water pressure is increased by the change in volume between the impeller
and the pump case. As a result, the increased water pressure enables the water pump to circulate the cooling water.

5
1

5
2

6
1 7 3
IAJ311160002-01

1. Water inlet 3. Key 5. Water pump impeller 7. Driveshaft

2. Water outlet 4. Water pump case 6. Under panel
1F-2 Power Unit Cooling System:

Schematic and Routing Diagram

Cooling Water Circulation Chart
CENFL3121602001
The water cooling system includes the lower unit water pump, lower unit to power unit water supply tube, power unit
water passages and thermostat.
This system cools both the power unit and exhaust and is shown in schematic form below.
If overheating occurs, the components of the cooling system must be inspected for blockage, corrosion build-up or
component damage.

CYLINDER BLOCK
(RETURN PASSAGE)

When open

THERMOSTAT

CYLINDER BLOCK

CYLINDER HEAD

CYLINDER BLOCK EXHAUST MANIFOLD

ENGINE HOLDER ENGINE HOLDER

DRIVESHAFT HOUSING DRIVESHAFT HOUSING FUEL COOLER

WATER TUBE PILOT WATER HOLE

WATER PUMP

WATER INLET
PROPELLER
EXHAUST OUTLET

WATER
IFL311160001-02
 Power Unit Cooling System: 1F-3

Diagnostic Information and Procedures

Powerhead Cooling System Diagnosis
CENFL3121604001

Condition Possible cause Correction / Reference Item

Overheating powerhead Water inlet screen obstructed. Clean.
Water passage obstructed. Clean or replace.
Pump plate not sealing. Check and repair.
Water pump impeller damage. Replace.
Water pump housing and/or plate worn. Replace.
Water pump housing seal worn. Replace.
Water tube grommet damaged. Replace.
Thermostat damaged / defective. Replace.
Water tube obstructed. Clean.
Water tube defective. Replace.
Overcooling powerhead Thermostat damaged / defective. Replace.

Service Instructions
Thermostat Removal and Installation 2) Remove the two bolts (2) securing the thermostat
CENFL3121606001 cover (3), then remove the cover and thermostat (4).
Removal
1) Remove the recoil starter (1).
Refer to “Recoil Starter Removal and Installation” in 2
Section 1J (Page 1J-3).

IFL311160003-01

IFL311160002-01

IFL311160004-01
1F-4 Power Unit Cooling System:

Installation Thermostat and Related Items Inspection

Installation is reverse order of removal with special CENFL3121606002

attention to the following steps. Inspect the thermostat in the following procedures:
1) Install seal (1) to thermostat cover (2). 1) Remove the thermostat.
Refer to “Thermostat Removal and Installation”
(Page 1F-3).
1
2) Inspect the thermostat.
If salt deposits, corrosion, wear or other damage is
found, clean or replace.
2

IFL311160005-01

2) Assemble thermostat (3) and thermostat cover (2) to

cylinder block and secure with bolts (4).
Tightening torque
Thermostat cover bolt (a): 11 N·m (1.1 kgf-m, 8.0 IAJ311160008-01
lbf-ft) 3) Check thermostat opening temperature as follows:
a) Insert a length of thread between thermostat
valve / body and suspend thermostat in a
container filled with water.
3 b) Place thermometer in container and heat water.
Observe water temperature when thermostat
valve opens and releases thread.
Thermostat operating temperature
Standard: 58 – 62 °C (136 – 144 °F)

IFL311160006-01
1

2 2
3

I9J011160002-01

1. Thermometer 3. Thermostat
2. Heater
4 (a)
IFL311160007-01
If thermostat valve does not open as specified
3) Install the recoil starter. above, or sticks in any position, replace it.
Refer to “Recoil Starter Removal and Installation” in
Section 1J (Page 1J-3).
 Power Unit Cooling System: 1F-5

4) Inspect thermostat cover. Replace if cracked, Water Pump Removal and Installation
distorted or other abnormal conditions are noted. CENFL3121606003

Check condition of seal. Replace seal if nicked, cut, Refer to “Water Pump Removal and Installation” in
worn or other abnormal condition are noted. Section 3A (Page 3A-6).

Water Pump Related Item Inspection

CENFL3121606004
Refer to “Water Pump and Related Items Inspection” in
Section 3A (Page 3A-8).

Water Tube Removal and Installation

CENFL3121606005
Removal
Refer to “Engine Holder / Driveshaft Housing / Mounts
Disassembly” in Section 2A (Page 2A-15).

IFL311160009-01
Installation
Refer to “Engine Holder / Driveshaft Housing / Mounts
5) Install the thermostat.
Assembly” in Section 2A (Page 2A-17).
Refer to “Thermostat Removal and Installation”
(Page 1F-3).
Water Tube Related Item Inspection
CENFL3121606006
Refer to “Engine Holder / Driveshaft Housing / Mounts
Related Component Inspection” in Section 2A (Page 2A-
21).
1G-1 Fuel System:

Fuel System
Power Head

Precautions
Precautions on Fuel System Service
CENFL3121700001
! WARNING
Service operation of any type performed on the fuel system involves a risk of fire and injury if proper
precautions are not taken.

Be sure to take the following precautions when working around gasoline or servicing the fuel system.
• Disconnect battery cables except when battery power is required for servicing / inspection.
• Keep the working area well ventilated and away from open flame (such as gas heater) or sparks.
• Do not smoke or allow anyone else to smoke near the working areas.
Post a “NO SMOKING” sign.
• Keep a fully charged CO2 fire extinguisher readily available for use.
• Always use appropriate safety equipment and wear safety glasses when working around a
pressurized fuel system.
• To avoid potential fire hazards, do not allow fuel to spill on hot engine parts or on operating
electrical components.
• Wipe up fuel spills immediately.
• Before loosening or disconnecting the fuel feed line, be sure to relieve the fuel system of fuel
pressure by following the fuel pressure relief procedure.
• When disconnecting a fitting on the fuel line, cover the fitting with a shop cloth to soak up the small
amount of fuel that may flow out from the disconnected fuel line. Put the used cloth in an approved
container.
• Since fuel hose connections vary with the pipe type, connect and clamp each hose using the correct
method for each specific connection.
After connecting a hose, check that there is no twist or kink in the hose.
• When installing hose clamps, position tabs to avoid contact with other parts.
• Be sure hoses do not contact rods, levers or other components with engine either operating or at
rest.
 Fuel System: 1G-2

General Description
Electronic Fuel Injection System Description
CENFL3121701001
The fuel injection system used by the DF25A/30A is a speed-density, multi-point, sequential, electronic fuel injection
type.
The fuel injection system is composed of the fuel line components, air intake components, and components for system
control (ECM, sensors, switches, etc.).

Fuel Injection Control System Outline

Sensors are mounted at precise locations on the motor to monitor the current conditions of engine operation and send
signals to the ECM.
Based on these signals, the ECM determines the optimum fuel injection time duration (fuel amount), fuel injection
timing (multi-point sequential timing) and controls the injector operating signals accordingly.
In regards to fuel injection timing, the fuel injection end timing is set depending on engine rpm. The ECM calculates
the amount of fuel injection based on the engines operating conditions, and determines the fuel injection start timing.
In the injection timing chart below, the injection end timing is set at 60° BTDC on the Ex. stroke.

Basic sensors
ECM
MAP sensor:
Informs ECM of intake manifold pressure. Fuel injection time duration
CKP sensor: (amount) is determined by
Informs ECM of engine speed and crankshaft angle. a digital map designed in
relation to intake manifold
Compensating sensors pressure and engine speed.
Cylinder temperature sensor:
Informs ECM of cylinder temperature.
IAT sensor:
Informs ECM of intake air temperature. Fuel amount compensation
TPS (Throttle position sensor):
Informs ECM of throttle opening angle.
Multi-point sequential timing
Others
CMP sensor:
Informs ECM of camshaft angle. Signal Signal Signal
Neutral switch:
Informs ECM of shift position (neutral or in-gear).

Fuel injector
IFL311170001-02

4 “A”
1

A A A

5
IFL311170002-02

1. ECM power source coil 3. ECM 5. Fuel injector

2. Rectifier/regulator No.1 4. CPU “A”: Sensor/switch signal input
1G-3 Fuel System:

Fuel Injection Timing Chart

30 signals / crankshaft 1 rotation

CKP sensor
signal

CMP sensor
signal
CMP sensor - 9 signals / 720° (crankshaft 2 rotation)

TDC
No.1 cylinder Cm. Ep. Ex. In.
TDC
No.3 cylinder In. Cm. Ep. Ex.
TDC
No.2 cylinder Ep. Ex. In. Cm.

Injection time duration Injection end timing: 60° BTDC on Ex.stroke

No.1 Injection
signal

No.3 Injection
signal

No.2 Injection
signal

Cm.: Compression, Ep.: Explosion, Ex.: Exhaust, In.: Intake,

IFL311170010-01

Fuel Injection Control Mode

Before start:
When the ignition switch is turned “ON” for remo-con model or starter is operated for tiller handle model, the ECM
receives a MAP sensor signal, indicating the static barometric pressure of the intake manifold.
This signal is used to compensate the fuel injection map.

When cranking:
Fuel is injected in each cylinder according to the “Start up mode” map which is based on the cylinder temperature and
intake air temperature (Sequential injection).

After start (Fast-idle function):

The fuel injection amount is controlled so that it is increased until the cylinder temperature comes to the normal
operating temperature.

When idling / trolling:

The fuel injection amount is controlled to maintain a stable engine speed at the specified idle / trolling rpm.

When running (normal operation):

ECM calculates the target air/fuel ratio on basis of signals from CKP sensor, MAP sensor, etc.
ECM compensates the basic fuel injection amount so as to obtain the calculated air/fuel ratio.

When accelerating:
The fuel injection amount is controlled to increase.

When decelerating:
The fuel injection amount is controlled to decrease.
 Fuel System: 1G-4

Fuel Delivery System Components Description

CENFL3121701002
The fuel delivery system is composed of the low pressure fuel line components (fuel tank, filter, pump etc.), fuel vapor
separator, high pressure fuel pump, fuel pressure regulator (located in the high pressure fuel pump), delivery pipe, fuel
injectors and hoses.
Fuel is supplied through the primer bulb, low pressure fuel filter, and low pressure fuel pump to the fuel vapor
separator.
Fuel flow from the fuel vapor separator is pressurized by the high pressure fuel pump and supplied through the fuel
delivery pipe to the fuel injectors.
The pressure regulator maintains fuel pressure in the feed line at absolute fuel pressure of approx. 300 kPa (3.0 kg/
cm2, 43 psi.). This pressure is maintained at a constant level.
When fuel feed line pressure exceeds more than approx. 300 kPa (3.0 kg/cm2, 43 psi.), the valve in the fuel pressure
regulator will open and return the excess fuel to the vapor separator chamber.
Pressurized fuel enters into the intake ports through the fuel injector based on the sequential signals supplied from the
ECM.

“A”
14

4
“C” 13 14
“B”
6 14
3
5
12
2

1 7 8

11
9
10
“D”
IFL311170003-09

1. Fuel tank 6. Float 11. High pressure fuel pump assembly “B”: Fuel vapor
2. Fuel primer bulb 7. Fuel cooler 12. Fuel pressure regulator “C”: Fuel return
3. Low pressure fuel filter 8. In-line fuel filter 13. Fuel delivery pipe “D”: Fuel drain
4. Low pressure fuel pump 9. Fuel drain body 14. Fuel injector
5. Fuel vapor separator 10. Drain screw “A”: Evaporation gas

Fuel Vapor Separator

The fuel vapor separator incorporates a float system that maintains a constant fuel level inside the separator chamber.
As the fuel level decreases, fuel flows into the vapor separator from the low pressure fuel pump.
The function of this unit is to separate vapors from fuel delivered by the low pressure fuel pump or fuel returned from
the fuel pressure regulator.
This vapor is routed through the evaporation hose to the atmosphere.

3
IFL311170004-04

1. Fuel inlet (from low pressure fuel pump) 3. Fuel outlet (to fuel cooler) 5. Return fuel inlet (from high pressure fuel pump / fuel pressure regulator)
2. Float 4. Air vent 6. Return vapor inlet (from high pressure fuel pump)
1G-5 Fuel System:

High Pressure Fuel Pump

The high pressure fuel pump is an “integral” type.
The pump is located under the intake manifold.
To supply the optimum fuel amount, the pump is driven by the duty cycle signal from the ECM.

4
5

2
IDK111170006-02

1. High pressure fuel pump 3. Fuel outlet 5. Fuel vapor/bubble (air) outlet
2. Fuel inlet 4. Return fuel outlet

Fuel Pressure Regulator

The fuel pressure regulator is located in the high pressure fuel pump.
The regulator’s function in the system is to maintain a constant fuel pressure relative to the injector while the engine is
operating.
Fuel pressure, adjusted by the regulator, is constantly maintained at absolute fuel pressure of approx. 300 kPa (3.0
kgf/cm2, 43 psi.).
By-pass fuel is returned to the fuel vapor separator chamber.

Fuel Injector
The fuel injector is an electromagnetic valve operated by a signal from the ECM.
When the injection signal is supplied to the fuel injector, the solenoid coil is energized pulling up the plunger.
This opens the injector valve and injects fuel.
Because the fuel pressure is kept constant, the amount of fuel injected is determined by the amount of time (duration)
the valve is open.

IFL311170014-01

1. Fuel injector
 Fuel System: 1G-6

High Pressure Fuel Pump Control System Description

CENFL3121701003
To supply the optimum fuel amount, the ECM controls the fuel pump drive duty cycle, a repeated “ON” / “OFF” signal,
at a specified rate (1 000 times a second).
Based on fuel injection amount, the ECM determines the optimum duty cycle (repeating “ON” time rate within a cycle)
and sends this signal to the fuel pump.

ECM Signal FP
Fuel pump
IDK111170007-02

3
4

CPU

5 6

2 FP
IFL311170005-01

1. Sensor/switch signal input 4. ECM power source coil

2. High pressure fuel pump 5. Rectifier/regulator No.1
3. ECM 6. Pump driver

Duty cycle signal for fuel pump (example: 80% duty)

“ON” time × 100 = duty (%)
1 cycle time

0.8 ms

OFF

ON Time
1 ms (1cycle)

IDK111170011-01

Control Modes
When cranking:
The fuel pump is controlled to operate at “start-up” mode.

When running (Normal operation):

The fuel pump is controlled to operate at a 10 – 100% duty cycle based on the current engine speed and fuel injection
amount.
1G-7 Fuel System:

Air Intake Components Description

CENFL3121701004
Air, after entering through the silencer case, passes through the throttle body and flows into the surge tank where it is
then distributed to the intake manifold.
Intake manifold pressure, monitored by the MAP sensor, is an indirect measurement of the intake air amount.
When the throttle is fully closed, the main supply of intake manifold air necessary to sustain engine idle passes
through the by- pass air passage.
To maintain engine idle speed at specification, the ECM controlled IAC valve supplies a regulated amount of additional
air through the IAC (idle air control) passage.

Air flow

7 2

8 1
6 4 3

5
IFL311170011-02

1. Throttle body 3. Intake manifold 5. MAP sensor 7. Air intake silencer

2. IAC valve 4. Throttle position sensor 6. IAT sensor 8. By-pass air screw
 Fuel System: 1G-8

Throttle Body By-pass air screw / passage

• The throttle body assembly consists of the main bore, Since the throttle valve is almost fully closed when idling
throttle valve, by-pass air passage, IAC passage, by- / trolling, the main flow of air necessary to maintain idling
pass air screw and TPS (Throttle Position Sensor). /trolling speed passes through the by-pass air passage.
The by-pass air adjustment screw controls the flow of air
• The throttle body adjusts the intake air amount with
through the passage and provides a means of partially
the throttle valve which is connected to the throttle
adjusting the total amount of air necessary for idling /
lever linkage.
trolling.
• The TPS installed on the throttle body informs of
throttle valve opening angle. NOTE

NOTE For the by-pass air screw adjustment

procedure, refer to “Idle Speed and Idle Air
Do not try to adjust or remove any of the Control (IAC) Duty Inspection” in Section 0B
throttle body component parts (Throttle (Page 0B-13).
position sensor, throttle valve, throttle stop
screw, etc.).
These components have been factory
adjusted to precise specifications.

3 2 1

IFL311170017-01

1. By-pass air screw

4
IFL311170016-01

1. Throttle body assembly 2. TPS

3. By-pass air screw 4. Throttle stop screw

IAC valve / passage

The IAC valve is a solenoid plunger type mounted on the intake manifold.
Its purpose is to control the amount of intake air flowing from the IAC passage.
The IAC valve is driven by the duty cycle signal from the ECM.

2
Air flow

3
1

IFL311170012-03

1. Throttle body 2. IAC valve 3. By-pass air screw

1G-9 Fuel System:

Idle Air Control System Description

CENFL3121701005
The ECM controls the duty cycle signal of the IAC valve to regulate a portion of the intake air flow to the intake
manifold.
This system is used for the following purposes:
• To keep idling / trolling at the specified speed.
• To improve drivability when decelerating. (Dash-pot effect)
• To improve engine starting and warm-up performance. (Fast-idle function)
The sensors / switch shown below monitor current engine condition and send signals to the ECM. Based on these
signals, the ECM determines the optimum duty cycle (repeating “ON” time rate within a cycle).
A repeating ON/OFF signal at a specified rate (10 times a second) is then sent to the IAC valve.

CKP sensor:
Informs ECM of engine speed.

MAP sensor: Signal

Informs ECM of intake manifold pressure.
ECM
TPS:
Informs ECM of throttle opening angle.

Cylinder temp. sensor:

Informs ECM of cylinder temperature. IAC valve
IDK111170013-01

IAC Valve Control Mode When running (normal operation):

Before started: The IAC valve is controlled to operate at 0 – 100% duty,
• On the tiller handle model; which depends on the current engine conditions.
The IAC valve is always closed when engine is not
running. (0% duty) When decelerating (dash-pot effect):
When the throttle valve is suddenly returned to full close
• On the remote control model;
and the throttle position sensor signal changes to “fully
The IAC valve is controlled to operate in 100% duty
closed”, the IAC valve operates at a controlled gradual
under the condition of ignition switch is ON but engine
return to idle / troll operating duty to prevent engine
is not running.
stalling or unstable running.
When cranking: NOTE
The IAC valve is controlled to operate at 100% duty.
Due to the limited intake air flow from the IAC
passage and in order to effectively use both
After start (fast-idle function):
the “Dash-pot effect” and “Fast-idle
The IAC valve is controlled to operate at 100% duty until
function”, the by-pass air screw must be
the timer, which was set according to cylinder
adjusted to provide IAC valve operation at 10
temperature at cranking, expires.
± 5% duty at the engine idling / trolling
specification.
When idling / trolling:
For the by-pass air screw adjustment
The IAC valve is controlled so that the engine speed is
procedure, refer to “Idle Speed and Idle Air
stable at the idling / trolling speed specified.
Control (IAC) Duty Inspection” in Section 0B
During this period, the IAC valve has a duty cycle of
(Page 0B-13).
approx. 10% but will vary slightly as idling / trolling
conditions change.
 Fuel System: 1G-10

Diagnostic Information and Procedures

Fuel Pressure Inspection 4) Connect special tools (pressure gauge, pressure
CENFL3121704001 hose and pressure joint) between fuel feed hose (1)
! WARNING and fuel delivery pipe as shown in figure.
Clamp the hose securely to ensure that no leaks
Gasoline is a flammable material that can
occur during checking.
cause fire hazard or burns.
! WARNING
Before starting the following procedure, be
sure to observe “Precautions on Fuel System Gasoline is a flammable material that can
Service” in order to reduce the risk or fire cause fire hazard or burns.
and personal injury.
A small amount of fuel may be released when
1) Relieve fuel pressure in fuel feed line. the fuel feed hose is disconnected.
Refer to “Fuel Pressure Relief Procedure” (Page 1G- Place container under the fuel feed hose or
15). fuel delivery pipe with a shop cloth so that
2) Remove STBD lower side cover. the released fuel is caught in the container or
Refer to “Lower Side Cover Removal and absorbed by the cloth. Place the fuel soaked
Installation” in Section 2A (Page 2A-3). cloth in an approved container.
3) Disconnect high pressure fuel feed hose (1) from
fuel delivery pipe (2). Special tool
(A): 09912–58442 (Fuel pressure gauge)
(B): 09912–58432 (Fuel pressure hose)
2 (C): 09912–58490 (3-way joint & hose)

(A)

1 (C)

(B)
IFL311170018-01

IFL311170019-01

(A)
2
(B)

(C)

IFL311170020-02

2. Fuel delivery pipe

1G-11 Fuel System:

5) Ensure emergency stop switch lock plate is in place. 10) After checking fuel pressure, remove fuel pressure
6) Turn the ignition switch ON. gauge.
7) Squeeze fuel primer bulb until you feel resistance.
Pull the starter grip sharply several times to fill the
high pressure fuel feed line with fuel.
Repeat this procedure 3 or 4 times to pressurize the
fuel system and then check fuel pressure.

IFL311170007-01

IAJ311170008-01 3. Joint nut

8) Check for any signs of fuel leakage.
9) Measure fuel pressure at cranking or idle speed 11) Reconnect fuel line.
operation. 12) Check the fuel system for leaks.
If out of specification, check each possibly defective
parts (high pressure fuel pump, fuel pressure
regulator, fuel injector, etc.).
Replace if found defective.
Fuel pressure
Standard: Approx. 300 kPa (3.0 kg/cm2, 43 psi)

! WARNING
Gasoline is a flammable material that can
cause fire hazard or burns.

The fuel feed line is under high fuel pressure,

make sure to release fuel pressure according
to the fuel pressure relief procedures
mentioned earlier.
Use the following procedures to remove the
fuel pressure gauge.
• Place a container under the joint to catch
the fuel.
• Cover the joint with rag and loosen joint
nut slowly to gradually release any
residual fuel pressure.
 Fuel System: 1G-12

Fuel System Diagnosis

CENFL3121704002

Condition Possible cause Correction / Reference Item

Engine will not start or Clogging, bending or improper routing of Clean, repair or replace.
hard to start. (Fuel does fuel hose.
not reach the fuel deliveryLow pressure fuel pump failure. Replace.
pipe.) High pressure fuel pump failure. Replace.
Fuel injector(s) failure. Replace.
Wiring connection failure. Repair or replace.
Engine will not start or Neutral switch failure. Replace.
hard to start. Throttle position sensor failure. Replace.
MAP sensor failure. Replace.
ECM failure. Replace.
Cylinder temp. sensor failure. Replace.
IAT sensor failure. Replace.
CKP sensor failure Replace.
CMP sensor failure Replace.
High pressure fuel pump failure. Replace.
Fuel hose improperly routed. Reroute properly.
Unstable idling / trolling Neutral switch failure. Replace.
or engine tends to stall. Throttle position sensor failure. Replace.
IAC control system failure. Check idle air control system.
IAC passage clogged. Clean.
ECM failure. Replace.
Wire continuity / connection failure. Repair or replace.
Fuel injector(s) clogged. Replace.
High pressure fuel pump failure. Check fuel pump and its circuit. Replace.
Fuel filter clogged. Clean or replace.
Clogging, bending or improper routing of Clean, reroute, repair or replace.
fuel hose.
Insufficient engine power Air leakage from air intake system. Repair or replace.
in high speed range. (Air
intake system failure.)
Insufficient engine power Fuel pressure too low. Check fuel pressure. Repair or replace.
in high speed range. Throttle position sensor failure. Replace.
(Control circuit or sensor ECM failure. Replace.
failure.)
Insufficient engine power Fuel injector(s) clogged. Replace.
in high speed range. Throttle position sensor failure. Replace.
(Engine internal parts or ECM failure. Replace.
electrical equipment
failure.)
1G-13 Fuel System:

Fuel Injection System Troubleshooting Step 4

CENFL3121704003
Tiller Handle Models Check wire circuit.
Before starting the troubleshooting, make sure that: • Disconnect connector from ECM.
• There is no self-diagnostic code indication. • Measure resistance between each “O/B”, “B/Br”, “R/
• Emergency stop switch plate is set in place. W” wire terminal of the fuel injector connector and
body ground.
Step 1
Is resistance infinity?
Check fuel injector operating sound.
• Check each injector for operating sound at engine Yes Go to step 5.
cranking. ()(Page 1G-19))
No “O/B”, “B/Br” and/or “R/W” wire(s) are
Do all injector make operating sound? shorted to ground.
Yes Fuel injector circuit is in good condition. Step 5
No Go to step 2. Check wire circuit.
• Connect the connector to ECM.
Step 2 • Measure voltage between each “O/B”, “B/Br”, “R/W”
Check fuel injector resistance. wire terminal of fuel injector connector and body
• Stop the engine, disconnect connectors from fuel ground with engine cranking.
injectors.
Special tool
• Check for proper connection to fuel injector at each : Stevens peak reading voltmeter CD-77
terminal.
Tester knob indication
• If good condition, check all fuel injector for
POS50
resistance. ()(Page 1G-19))
Is voltage 0 V?
Are all injectors in good condition?
Yes Go to step 6.
Yes Go to step 3.
No “O/B”, “B/Br” and/or “R/W” wire(s) are
No Faulty fuel injector.
shorted to power supply circuit.
Step 3
Step 6
Check fuel injector power supply.
Check fuel injector operating signal.
• Measure voltage between each “Gr” wire terminal of
• Connect connectors to each fuel injector and ECM.
fuel injector connector and engine body ground with
engine cranking. • Measure fuel injector operating signal between each
“32”, “33”, “34”, terminal of ECM and body ground.
Special tool ()(Page 1G-20))
: Stevens peak reading voltmeter CD-77
Is voltage approx. 20 V or over?
Tester knob indication
POS50 Yes If check result is satisfactory, substitute a
known-good ECM and recheck.
Is voltage 5 V or over?
No “O/B”, “B/Br” and/or “R/W” wire(s) are
Yes Go to step 4. open circuit.
No • “Gr” wire open or shorted.
• If it is in good condition, check ECM
power source and ground circuit.
 Fuel System: 1G-14

Remote Control Models Step 4

Before starting the troubleshooting, make sure that: Check wire circuit.
• There is no self-diagnostic code indication. • Turn “OFF” ignition switch.
• Emergency stop switch plate is set in place. • Disconnect connector from ECM.
Step 1 • Measure resistance between each “O/B”, “B/Br”, “R/
Check fuel injector operating sound. W” wire terminal of the fuel injector connector and
body ground.
• Check each injector for operating sound at engine
cranking. ()(Page 1G-19)) Is resistance infinity?
Do all injectors make operating sound? Yes Go to step 5.
Yes Fuel injector circuit is in good condition. No “O/B”, “B/Br” and/or “R/W” wire(s) are
shorted to ground.
No Go to step 2.
Step 5
Step 2
Check wire circuit.
Check fuel injector resistance.
• Connect connector to ECM.
• Turn ignition switch off, disconnect connectors from
fuel injectors. • Measure voltage between each “O/B”, “B/Br”, “R/W”
wire terminal of fuel injector connector and body
• Check for proper connection to fuel injector at each
ground with ignition switch turned “ON”.
terminal.
• If good condition, check all fuel injector for Is voltage 0 V?
resistance. ()(Page 1G-19))
Yes Go to step 6.
Are all injectors in good condition?
No “O/B”, “B/Br” and/or “R/W” wire(s) are
Yes Go to step 3. shorted to power supply circuit.

No Faulty fuel injector. Step 6

Check fuel injector operating signal.
Step 3
• Connect connectors to each fuel injector and ECM
Check fuel injector power supply.
with ignition switch turned “OFF”.
• Measure voltage between each “Gr” wire terminal of
• Measure fuel injector operating signal between each
fuel injector connector and engine body ground with
“32”, “33”, “34” terminal of ECM and body ground.
ignition switch turned “ON”.
()(Page 1G-20))
Is voltage 10 – 14 V?
Is voltage approx. 20 V or over?
Yes Go to step 4.
Yes If check result is satisfactory, substitute a
No • “Gr” wire open or shorted. known-good ECM and recheck.
• If it is in good condition, check ECM No “O/B”, “B/Br” and/or “R/W” wire(s) are
power source and ground circuit. open circuit.
1G-15 Fuel System:

Service Instructions
Fuel Pressure Relief Procedure Fuel Line Removal and Installation
CENFL3121706001 CENFL3121706002
After making sure that engine is cold, relieve fuel Pay special attention to the following points when
pressure as follows. removing or installing fuel hoses.
1) Stop the engine.
Ensure emergency stop switch lock plate is in place.
! WARNING
2) Disconnect high pressure fuel pump lead wire Gasoline is a flammable material that can
connector (1) at high pressure fuel pump. cause fire hazard or burns.

Before starting the following procedure, be

sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
1 and personal injury.

• The fuel feed line is under high pressure, use special

care when servicing it.
• Spilled gasoline should be wiped off immediately.
• Perform the following checks to ensure proper and
safe operation of the repaired unit.
IFL311170021-01
– Check fuel hose routing.
3) Disconnect all ignition coil primary lead wire Refer to “Fuel/Water Hose Routing” in Section 4B
connectors (2). (Page 4B-1).
Turn the ignition switch ON.
– Check for fuel leakage.
Refer to “Fuel Leakage Check Procedure” (Page
1G-15).

Fuel Line Inspection

CENFL3121706003
Visually inspect fuel lines for evidence of fuel leakage,
2 cracking, deterioration, or damage. Make sure all clamps
are secure. Replace parts as needed.

Fuel Leakage Check Procedure

CENFL3121706004
After performing any fuel system service, always be sure
IFL311170022-01
there is no fuel leakage by checking as follows.
4) Crank the engine several times to dissipate fuel
pressure in lines. 1) Shift into “Neutral” position.
5) Make sure fuel pressure has been removed by 2) Ensure emergency stop switch lock plate is in place.
pinching high pressure fuel hose between finger tips 3) Squeeze fuel primer bulb until you feel resistance.
(line should feel soft without pressure). 4) Turn the ignition switch ON.
5) Pull the starter grip sharply several times.
6) Repeat step 3 and 5 to fill the high pressure fuel feed
line with fuel.
7) Once pressurized, check all connections and
components for any signs of leakage.

IFL311170024-01
IAJ311170008-01
6) Upon completion of servicing, connect ignition coil
primary lead wire and high pressure fuel pump lead
wire.
 Fuel System: 1G-16

Inspection of Fuel Hose Connections Fuel Vapor Separator Removal and Installation
CENFL3121706005 CENFL3121706006
Note that the fuel hose connection varies with each type NOTICE
of pipe. Be sure to connect and clamp each hose Disassembling the fuel vapor separator can
correctly by referring to the figure. lead to troubles.
• For type “A” (short barbed end) pipe, the hose must
completely cover pipe. The fuel vapor separator is a non-repairable
Type “A” component.
Do not attempt to disassemble the fuel vapor
1
2 separator.
It must be replaced as a complete unit if it is
defective.

Removal
1) Loosen the fuel drain screw (1) and drain the
“a” 3
gasoline into a suitable container.
I9J011170012-01

1. Clamp (Clip) 3. Joint pipe

2. Hose “a”: 3 – 7 mm (0.1 – 0.3 in)

• For type “B” (bent end) pipe, hose must cover the
straight part of pipe by 20 – 30 mm (0.8 – 1.2 in.). 1
Type “B”

“b” IFL311170025-01

“a” 2) Remove the intake manifold assembly.

Refer to “Intake Manifold Removal and Installation”
I9J011170013-01 in Section 1D (Page 1D-6).
“a”: 3 – 7 mm (0.1 – 0.3 in) “b”: 20 – 30 mm (0.8 – 1.2 in) 3) Remove the bolts and fuel vapor separator (2).

• For type “C” pipe, hose must fit up against the flanged
part of pipe. 2
Type “C”

“a”
I9J011170014-01

“a”: 3 – 7 mm (0.1 – 0.3 in)

IFL311170026-01

• For type “D” pipe, the hose must cover the pipe by 20
– 30 mm (0.8 – 1.2 in.).
Type “D”

“b”
“a”
I9J011170015-01

“a”: 3 – 7 mm (0.1 – 0.3 in) “b”: 20 – 30 mm (0.8 – 1.2 in)

1G-17 Fuel System:

4) Disconnect the fuel outlet hose (3), evaporation hose Fuel Vapor Separator Inspection
(4), fuel return hose (5) and fuel vapor hose (6) from CENFL3121706007

fuel vapor separator. NOTICE

Disassembling the fuel vapor separator can
4 lead to troubles.

The fuel vapor separator is a non-repairable

component.
6 Do not attempt to disassemble the fuel vapor
5
separator.
It must be replaced as a complete unit if it is
defective.
3
Fuel Vapor Separator Assembly
Inspect the fuel vapor separator.
IFL311170027-01
If leakage, cracks, damage or other abnormal condition
is found, replace fuel vapor separator assembly.
Installation
Installation is in the reverse order of removal with special
attention to the following steps.
• Install the fuel vapor separator, then tighten the bolts
securely.
• Install the intake manifold assembly.
Refer to “Intake Manifold Removal and Installation” in
Section 1D (Page 1D-6).
• Check to ensure that all removed parts are back in
place.
• Check hose and wire routing.
Refer to “Fuel/Water Hose Routing” in Section 4B IFL311170028-01

(Page 4B-1) and “Wiring Harness Routing Diagram” in

Section 4A (Page 4A-7).
• Check for fuel leakage.
Refer to “Fuel Leakage Check Procedure” (Page 1G-
15).
 Fuel System: 1G-18

High Pressure Fuel Pump Removal and Installation

Installation Installation is in the reverse order of removal with special
CENFL3121706008 attention to the following steps.
NOTICE
• Install the high pressure fuel pump, then tighten bolt
Disassembling the high pressure fuel pump securely.
can lead to troubles.
• Install the intake manifold assembly.
Refer to “Intake Manifold Removal and Installation” in
The high pressure fuel pump is a non-
Section 1D (Page 1D-6).
repairable component.
Do not attempt to disassemble the high • Check hose and wire routing.
pressure fuel pump. Refer to “Fuel/Water Hose Routing” in Section 4B
It must be replaced as a complete unit if it is (Page 4B-1) and “Wiring Harness Routing Diagram” in
defective. Section 4A (Page 4A-7).
• Check for fuel leakage.
Removal Refer to “Fuel Leakage Check Procedure” (Page 1G-
1) Remove the intake manifold assembly. 15).
Refer to “Intake Manifold Removal and Installation”
in Section 1D (Page 1D-6). High Pressure Fuel Pump Inspection
CENFL3121706009
2) Remove the high pressure fuel pump (1) from intake
1) Disconnect pump lead wire connector from high
manifold.
pressure fuel pump.
2) Check each coil of fuel pump for resistance.
Fuel pump resistance
Terminals Resistance
Between “1” and “2”
Between “2” and “3” 2.0 – 2.6 Ω
1 Between “3” and “1”

1
IFL311170029-01 2
3) Disconnect the fuel inlet hose (2) and outlet hose (3). 3
Disconnect the fuel vapor hose (4) and fuel return
hose (5).

5 4

IFL311170031-01

If out of specification, replace high pressure fuel

pump.
3

IFL311170030-02
1G-19 Fuel System:

Fuel Injector Inspection with Injector in Place Individual Fuel Injector Operating Sound
CENFL3121706010
Inspection
1) Using a sound scope or equivalent, check the CENFL3121706011
operating sound of the fuel injector when the engine 1) Disconnect all ignition coil primary lead wire
is running or cranking. connectors from the ignition coil.
Injector operating sound cycle should vary according 2) Disconnect the fuel injector lead wire connector and
to engine speed. connect the test cord.
If no sound or an unusual sound is heard, check
injector circuit (wire or connector) or injector. Special tool
(A): 09930–89260 (Injector test cord (A))

(A)

“Click”
1

IFL312170001-01
IFL311170034-01
1. Injector body
3) Connect the Gray wire to 12 V battery negative
2) Disconnect the lead wire connector from the fuel terminal.
injector. 4) Momentarily touch the Black/Yellow wire to battery
3) Connect a digital tester between the terminals of the positive (+) terminal and check for injector operating
injector and measure resistance. sound.
If out of specification, replace the fuel injector. If out of specification, replace fuel injector.

Special tool NOTICE

: 09900–25008 (Multi circuit tester set) If battery power is applied too long in any of
Tester knob indication the following tests, the coil of the fuel injector
Resistance (Ω) may burn.

Fuel injector resistance Fuel injector test must be completed within

Standard: 10 – 14 Ω few seconds to avoid burning of the coil.

Fuel injector operating sound

“Click”

“Click”

IFL311170033-01

4) Connect the lead wire connector to the fuel injector

securely.
IFL311170008-04
 Fuel System: 1G-20

Fuel Injector Operating Signal Inspection

CENFL3121706012

(A)

1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
14 15 16 17 31 32 33 34
2

32 33 34

IFL311170009-01

1. ECM 2. Black connector

Special tool
(A): 09930–89290 (18 pin & 34 pin test cord)
: Stevens peak reading voltmeter CD-77
Tester knob indication
POS 50
1) Disconnect all ignition coil primary lead wire connectors from the ignition coil.
2) Connect the test cord between the ECM and wire harness as shown in figure.
3) Connect the tester probe (“–”, Black) to No.9 terminal (or to body ground) as shown in figure.
4) Connect the tester probe (“+”, Red) to each terminal.
Injector Terminal Wire color (Engine harness)
No.1 32 O/B
No.2 33 B/Br
No.3 34 R/W

5) Ensure emergency stop switch lock plate is in place.

6) Turn the ignition switch ON.
7) Crank the engine and measure the voltage. If out of specification, inspect the related parts as described in “Fuel
System Diagnostic Information/Fuel Injection System Troubleshooting”.
Refer to “Fuel System Diagnosis” (Page 1G-12) and “Fuel Injection System Troubleshooting” (Page 1G-13).
Fuel injector operating signal
Standard: Approx. 20 V or over
1G-21 Fuel System:

Fuel Injector Removal and Installation ! WARNING

CENFL3121706013
Removal Gasoline is a flammable material that can
1) Relieve the fuel pressure in the fuel feed line cause fire hazard or burns.
according to “Fuel Pressure Relief Procedure”.
Refer to “Fuel Pressure Relief Procedure” (Page 1G- A small amount of fuel may be released when
15). the fuel injector is removed from delivery
2) Disconnect the three fuel injector connectors (1). pipe.
Remove the three harness clamps (2). Place a shop cloth under fuel injector before
removal to absorb any fuel released.
Dispose of fuel soaked cloth in appropriate
container.

5) To remove the fuel injector clip (5), open the clip’s

open end slightly while pulling the clip (5) out from
2 injector body.
1

IFL311170035-01
5
3) Loosen the clamp and place a large cloth over the
end of fuel feed hose (3).
Slowly pull the fuel feed hose from the fuel delivery
pipe.
Drain any excess fuel in the hose into a small
container.
IFL311170038-02

6) Remove each injector (6) from the delivery pipe.

3 6

IFL311170036-01

4) Remove two bolts and fuel delivery pipe (4) (with fuel
injectors). IFL311170039-01

7) To remove the hose fitting clip (8), open the clip’s

open end slightly while pushing the clip out from
hose fitting (7).
Detach the hose fitting from the fuel delivery pipe.
4

8
7

IFL311170037-01

IFL311170040-02
 Fuel System: 1G-22

Installation 3) Install the fuel delivery pipe with fuel injectors (4) to
Installation is in the reverse order of removal with special cylinder head.
attention to the following steps.

! WARNING
Failure to take proper precaution when 4
reinstalling fuel injector can result in fuel
leakage or damage.

Do not re-use O-ring once removed. Always

use new parts.

1) Replace the injector O-rings (1) with new one using

care to avoid nicks or cuts during installation. IFL311170043-01

Apply thin coat of fuel to the new O-rings. 4) Tighten the delivery pipe bolts (5) to the specified
torque.
Tightening torque
Fuel delivery pipe bolt (a): 11 N·m (1.1 kgf-m, 8.0
lbf-ft)
1 “A”

5 (a)
IFL311170041-01

“A”: Apply fuel to O-rings

2) Install the fuel injector (2) to the fuel delivery pipe.

Slide the clip (3) into the position to fix the fuel IFL311170044-01
injector
5) Reconnect the fuel feed hose and fuel line securely.
6) Connect the lead wire connector to the injectors
securely.
7) Make sure the emergency stop switch lock plate is in
place.
2 Shift into “NEUTRAL” position.
8) Squeeze the fuel primer bulb until you feel
3 resistance.
9) Pull the starter grip sharply several times.
10) Repeat step 8 and 9 to fill the high pressure fuel feed
line with fuel.
IFL311170042-01 Check for fuel leaks around the fuel injector.
1G-23 Fuel System:

Low Pressure Fuel Pump Removal and Installation

Installation Installation is in the reverse order of removal with special
CENFL3121706014 attention to the following steps.
NOTICE
Disassembling the low pressure fuel pump NOTE
can lead to troubles. • Before installing the fuel pump, rotate the
crankshaft to bring No.1 (top cylinder)
The low pressure fuel pump is a non- piston to Top Dead center on the
repairable component. compression stroke.
Do not attempt to disassemble the low
• Do not reuse O-ring once removed. Always
pressure fuel pump.
use a new O-ring.
It must be replaced as a complete unit if it is
defective. Tighten the low pressure fuel pump bolts (1) to the
specified torque.
Removal
1) Disconnect inlet hose (1) and outlet hose (2) from Tightening torque
low pressure fuel pump. Low pressure fuel pump bolt (a): 11 N·m (1.1 kgf-m,
8.0 lbf-ft)
2) Remove two bolts (3).

2 1

3 1 (a)

IFL311170047-01
IFL311170045-01

3) Remove the low pressure fuel pump (4) and O-ring

(5).
Note position before removing pump rod (6).

4
IFL311170046-01
 Fuel System: 1G-24

Low Pressure Fuel Pump Inspection In-line Fuel Filter Removal and Installation
CENFL3121706015 CENFL3121706016
NOTICE Removal
Disassembling the low pressure fuel pump
! WARNING
can lead to troubles.
Gasoline is a flammable material that can
The low pressure fuel pump is a non- cause fire hazard or burns.
repairable component.
Do not attempt to disassemble the low Before starting the following procedure, be
pressure fuel pump. sure to observe “Precautions on Fuel System
It must be replaced as a complete unit if it is Service” (Page 1G-1) in order to reduce the
defective. risk or fire and personal injury.

Fuel Pump Assembly 1) Remove the STBD lower side cover.

Inspect the fuel pump. Refer to “Lower Side Cover Removal and
If leakage, cracks, damage or other abnormal condition Installation” in Section 2A (Page 2A-3).
is found, replace fuel pump assembly.
2) Drain fuel by loosening the screw (1).
3) Remove the bolt (2) securing high pressure fuel
pump bracket.

IDK111170052-01

IFL311170049-02

4) Loosen the clips and place a large cloth over the in-
line fuel filter (3).
Disconnect three fuel hoses from the in-line fuel
filter.

IFL311170048-01

IFL311170050-02

5) Drain any excess fuel in filter into a small container.

Installation
Installation is reverse order of removal with special
attention to the following steps.
• Check fuel hose routing.
Refer to “Fuel/Water Hose Routing” in Section 4B
(Page 4B-1).
• Check for fuel leakage.
Refer to “Fuel Leakage Check Procedure” (Page 1G-
15).
1G-25 Fuel System:

Fuel Tank Construction

CENFL3121706017

2 4
5

5
6
5

1 5
3

8 12

9
10
7
11
13

IFL311170013-03

1. Fuel plug 6. Fuel primer bulb 11. O-ring

2. Fuel hose assembly 7. Fuel tank body 12. Fuel tank cap
3. Socket 8. Fuel connector plug 13. Fuel tank cap gasket
4. Socket 9. Outlet
5. Clip 10. Outlet filter
 Fuel System: 1G-26

Fuel Tank Disassembly and Reassembly Fuel Hose

CENFL3121706018 Inspect the fuel hoses. If cut, crack, leakage, abrasion,
When disassembling or reassembling the fuel tank, refer
tear or deterioration is found, replace the hoses.
to “Fuel Tank Construction” (Page 1G-25).
Fuel Tank Body
Fuel Tank Components Inspection Inspect the fuel tank. If crack, leakage or deterioration is
CENFL3121706019
Fuel Connector found, replace the tank.
Inspect the fuel connector and connector plug. If If water or other contamination is found, drain and clean
leakage, deterioration or other damage is found, replace the tank.
the connector and/or plug.

1
2
2

1 IFL311170015-01

IAJ311170015-01
Fuel Tank Cap
1. Connector 2. Connector plug
Check that the fuel tank vent opens and relieves internal
tank pressure properly.
Fuel Primer Bulb
If vent is suspect, replace the tank cap.
Inspect the fuel primer bulb.
If crack, leakage or deterioration is found, replace the
bulb.
If the check valve function is defective, replace the bulb.

IAJ311170018-01

IAJ311170016-01
1H-1 Ignition System:

Ignition System
Power Head

General Description
Ignition System Description
CENFL3121801001
A digital CDI (condenser discharged ignition) system is employed on the DF25A/30A.
A condenser built in the ECM stores an electrical energy supplied from the ECM power source.
The electrical energy stored in the condenser is released to the ignition coil primary windings by the ignition timing
signal calculated by the ECM, then a high surge voltage is generated in the ignition coil secondary windings and
wakes ignition spark.

“A”

“B”
3

IFL311180006-02

1. ECM 3. Ignition coil “B”: Sensor/switch signal input

2. Ignition driver circuit “A”: ECM power source (from power source coil)
 Ignition System: 1H-2

Ignition Control Description

CENFL3121801002
Sensors at specific points on the engine monitor current engine conditions and send signals to the ECM.
Based on these signals, the ECM determines the optimum ignition timing and releases voltage to the primary winding
of the ignition coil.

Basic sensors ECM

MAP sensor: Ignition timing is determined by a
Informs ECM of intake manifold pressure. digital map designed in relation to
intake manifold pressure and
CKP sensor: engine speed.
Informs ECM of engine speed and crankshaft angle.

Compensating sensors
Cylinder temperature sensor:
Informs ECM of cylinder temperature. Ignition timing compensation
Throttle position sensor:
Informs ECM of throttle opening angle.
Neutral switch:
Informs ECM of shift position and change. Signal Signal Signal
IAT sensor:
Informs ECM of intake air temperature. Ign. coil Ign. coil Ign. coil

Spark plug
IFL311180001-02

Ignition Specification
Ignition type Digital CDI
Advance Electronic microcomputer control
0° ± 7° BTDC – 25° BTDC (DF25A)
Ignition timing
0° ± 7° BTDC – 25° BTDC (DF30A)
Firing order 1–3–2

Ignition Timing Control Mode

• When cranking
The ignition timing is fixed at 5° BTDC until the engine starts.
• When operating (normal operation)
The ignition timing ranges between BTDC 0° ± 7° – 25°, depending on current engine operating conditions.
1H-3 Ignition System:

Component Location
Ignition System Components Location
CENFL3121803001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-7).

Diagnostic Information and Procedures

Ignition System Symptom Diagnosis
CENFL3121804001

Condition Possible cause Correction / Reference Item

Engine cranks, but will Loose connection or disconnection of Connect securely.
not start or weak spark. lead wire.
(No spark) Faulty spark plug(s). Replace.
Faulty ignition coil. Replace.
Faulty CKP sensor. Replace.
Faulty CMP sensor. Replace.
Faulty power source coil. Replace.
Faulty ECM. Replace.
Faulty emergency stop switch. Replace.
Faulty neutral switch. Replace.
Spark plug is wet or Incorrect gasoline. Change.
quickly becomes fouled Incorrect spark plug. Replace.
with carbon.
Spark plug quickly Worn piston ring. Replace.
become fouled with oil or Worn piston. Replace.
carbon. Worn cylinder. Replace.
Excessive valve stem to valve guide Replace.
clearance.
Worn valve stem seal. Replace.
Spark plug electrodes Incorrect spark plug. Change.
overheat or burn. Overheated engine. Tune-up.
Loose spark plug. Tighten.
 Ignition System: 1H-4

Ignition System Troubleshooting Step 6

CENFL3121804002
Perform the following ignition system tests when the Measure the ignition coil primary peak voltage.
engine is hard to start in order to determine if the cause Refer to “Ignition Coil Primary Peak Voltage
is in the ignition or another system. Inspection” (Page 1H-7).
Is the peak voltage OK?
Step 1
Check the ignition system connector for poor Yes Poor connection of the spark plug.
connections.
No Go to step 7.
Is there connection in the ignition system
connectors? Step 7
Check ignition coil resistance.
Yes Go to step 2.
Refer to “Ignition Coil Inspection” (Page 1H-6).
No Poor connection of connectors. Is result OK?
Step 2 Yes Go to step 8.
Check spark condition.
No Faulty ignition coil.
Is result OK?
Step 8
Yes Go to step 13.
• Check the spark plug cap for any evidence of the
No No or weak sparks. Go to step 3. high-tension leak.
• Check spark plug cap resistance.
Step 3
Check if the spark plug is in good condition. Are result OK?
Is result OK? Yes Go to step 9.
Yes Go to step 4. No Faulty spark plug cap.
No Replace spark plug with a new one. Step 9
Check CKP sensor resistance.
Step 4 Refer to “CKP Sensor Inspection” (Page 1H-7).
• Disconnect the emergency stop switch lead wire
connector. Is result OK?
• Check spark condition at engine cranking. Yes Go to step 10.
Is result OK? No • Check air gap between CKP sensor
Yes Check and/or replace emergency stop and flywheel reluctor bars.
switch. • Adjust CKP sensor air gap.

No Go to step 5. • Replace CKP sensor or flywheel.

Step 5 Step 10
Check neutral switch condition. Check CMP sensor.
Refer to “Neutral Switch Inspection” in Section 1I Refer to “CMP Sensor Inspection” in Section 1C (Page
(Page 1I-17). 1C-10).

Is result OK? Is result OK?

Yes Go to step 6. Yes Go to step 11.

No Faulty neutral switch. No • Faulty CMP sensor.

• Check CMP sensor trigger vane.
• Replace CMP sensor or camshaft
pulley.
1H-5 Ignition System:

Step 11 Step 12
Check ECM power source. Substitute a known-good ECM then repeat step 2.
• Check ECM power source coil resistance. Is check result of step 2 satisfactory?
Refer to “ECM Power Source Coil Inspection” (Page
1H-7). Yes • Faulty ECM.
• Check rectifier/regulator No.1. • Replace ECM.
Refer to “Rectifier / Regulator Inspection” in Section
1K (Page 1K-9). No Open or short circuit in wire harness.

Is result OK? Step 13

Check the ignition timing by using timing light. (BTDC
Yes Go to step 12.
0° at 1 000 r/min)
No • Faulty ECM power source coil. Is result OK?
• Faulty rectifier/regulator No.1.
Yes System is in good condition.

No Faulty ECM.

Service Instructions
Spark Plug Removal and Installation 3) Remove the bolt (2) and ignition coil (3).
CENFL3121806001
Refer to “Spark Plug Removal and Installation” in
Section 0B (Page 0B-6).

Spark Plug Inspection 3

CENFL3121806002 2
Refer to “Spark Plug Inspection and Cleaning” in Section
0B (Page 0B-7).

Ignition Coil Removal and Installation

CENFL3121806003
Removal
1) Remove PORT lower side cover. IFL311180008-01
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3). Installation
2) Disconnect the ignition coil primary lead wire Installation is in the reverse order of removal.
connector (1).

IFL311180007-01
 Ignition System: 1H-6

Ignition Coil Inspection 3) Measure resistance.

CENFL3121806004
NOTE Primary coil resistance
0.17 – 0.23 Ω
Always disconnect the battery cable from
battery before commencing electrical If measurement is out of specification, replace the
resistance check. ignition coil.

Special tool Secondary Side

(A): 09900–25008 (Multi circuit tester set)
1) Remove the spark plug cap (4) from the high-tension
Tester knob indication cord.
Resistance (Ω)
Primary Side
1) Disconnect ignition primary coil lead wires.
4

IFL311180010-02

2) Connect the tester probe to Black coil lead wire and

high-tension cord as shown.
Tester probe connection
IFL311180009-01 Ignition coil
Red (+) Black (–)
2) Connect the tester probe to the coil lead wires as No.1
shown. No.2 High tension cord Black
Tester probe connection No.3
Ignition coil
Red (+) Black (–)
No.1
No.2 Orange Black
No.3

2
1

3
1

(A)
IFL311180003-01

1. Black lead wire

2. Orange lead wire
3. High tension cord
(A)
IFL311180002-01

1. Black lead wire 2. Orange lead wire 3) Measure resistance.

Secondary coil resistance
4.8 – 7.2 kΩ
If measurement is out of specification, replace the
ignition coil.
1H-7 Ignition System:

Spark Plug Cap Inspection 3) Turn the ignition switch ON. (Remote control model)
CENFL3121806005
Measure the spark plug cap resistance in the following 4) Connect the tester probe Red (+) to each terminal,
procedure. one at a time to test each circuit.
Terminal
Special tool No.1 ignition coil 17
: 09900–25008 (Multi circuit tester set) No.2 ignition coil 16
Tester knob indication No.3 ignition coil 15
Resistance (Ω)
5) Connect the tester probe Black (–) to No.9 terminal
1) Remove the spark plug cap from high-tension cord. (or to body ground).
2) Connect the tester probe to spark plug cap as 34-pin test cord (White connector)
shown.
Spark plug cap resistance 9
Standard: 8 – 12 kΩ 15 16 17

IFL311180005-01

6) Remove all spark plugs.

7) Crank with the recoil starter or starter motor, then
measure voltage.
Ignition coil primary peak voltage
Standard: 100 V or over
If measurement is out of specification, inspect the
IFL311180011-01
related parts.
3) If measurement is out of specification, replace the Refer to “Ignition System Symptom Diagnosis”
spark plug cap. (Page 1H-3) and “Ignition System Troubleshooting”
4) Connect the spark plug cap to high-tension cord. (Page 1H-4).

Ignition Coil Primary Peak Voltage Inspection CKP Sensor Inspection

CENFL3121806006 CENFL3121806007
Refer to “CKP Sensor Peak Voltage Inspection” in
Special tool
Section 1C (Page 1C-6) and “Resistance Check” in
(A): 09930–89290 (18 pin & 34 pin test cord)
Section 1C (Page 1C-5).
: Stevens peak reading voltmeter CD-77
Tester knob indication ECM Power Source Coil Inspection
POS 500 CENFL3121806008
Refer to “ECM Power Source Input Voltage Inspection”
1) Disconnect wire harness connector from ECM. in Section 1C (Page 1C-6) and “Resistance Check” in
2) Connect the 34 pin test cord between ECM and wire Section 1C (Page 1C-5).
harness as shown in figure.
Emergency and Engine Stop Switch Inspection
CENFL3121806009
1 Refer to “Emergency and Engine Stop Switch
Inspection” in Section 1C (Page 1C-15).
(A)

1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
14 15 16 17 31 32 33 34

IFL311180004-01

1. ECM 2. White connector

 Starting System: 1I-1

Starting System
Power Head

General Description
Electric Starter System Description
CENFL3121901001
The starting circuit consists of the battery, starting motor, starter button, ignition switch, neutral switch, starter motor
relay and related electrical wiring.
These components are connected electrically as shown in the figure below.
In the circuit shown in the figure, the starter relay coils is magnetized when the starter button is depressed or the
ignition switch is closed (turned to “START” position.), then starter motor relay closed its circuit.
Resulting starter pinion is made to mesh with flywheel ring gear by rotation of the starter motor armature.
After starting the engine, starter pinion is driven faster than the starter motor shaft and forced to move down the shaft
out of mesh with the flywheel ring gear.

Starting system circuit for tiller handle models

R M
6

W/R W/R R R
1
Br Br 3 4

Br R/W

G Y/G G Bl/W R B
2 Br B

+ –

5
IFL311190001-03

1. Starter button 3. Fuse (30 A) 5. Battery

2. Neutral switch 4. Starter motor relay 6. Starter motor
1I-2 Starting System:

Starting system circuit for remote control models

7 R

R B
M R
R
9
R/W

Bl/W

8 Br G
3
Y/G G
6 B Br
PUSH FREE ST IG OFF
GND B
STOP G
BATT W B 3
1 IG Gr
START Br
W W R G 25
B.Z
O
Br Br Br 4
RESET
Bl/O 22
PUSH TURN
G G Bl/O
Gr Gr Gr R/Y 5
2
5
B B B

IFL311190002-03

1. Ignition switch 4. ECM 7. Starter motor relay

2. Emergency stop switch 5. Fuse (10 A) 8. Battery
3. Neutral switch 6. Fuse (30 A) 9. Starter motor

Start-In-Gear Protection System Description

CENFL3121901002
The neutral switch opens the starter circuit to prevent accidental engaging of starter motor whenever the shift is set in
forward or reverse.
The switch is operated by clutch lever through push rod and notch ball.

3
2

1
IFL311190018-03

1. Clutch lever 3. Switch push rod

2. Neutral switch 4. Ball
 Starting System: 1I-3

Component Location
Starting System Components Location
CENFL3121903001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-7).

Diagnostic Information and Procedures

Starter System Symptom Diagnosis
CENFL3121904001

Condition Possible cause Correction / Reference Item

Motor not running. (No Poor or broken battery connection. Replace.
operating sound of starter Loose or corroded battery connection. Repair or retighten.
motor relay.) Weak or shorted battery. Replace or recharge battery.
Defective neutral switch. Neutral switch inspection. Replace.
Fuse blown. Replace.
Defective starter button. Starter button inspection. Replace.
Defective ignition switch. Ignition switch inspection. Replace.
Open circuit between starter button and Repair.
starter motor relay.
Lead wire disconnected or loose. Retighten.
Poor contacting action of starter button. Replace. Starter button inspection.
Defective starter motor relay. Starter motor relay inspection.
Motor not running. Weak or shorted battery. Replace or recharge battery.
(Operating sound of Battery voltage too low due to battery Replace battery.
starter motor relay heard.) deterioration.
Loose or corroded battery connection. Repair or retighten.
Burnt main contact point, or poor Replace starter motor relay. Starter motor relay
contacting action of starter motor relay. inspection.
Brushes are seating poorly or worn. Replace or repair. Brushes inspection.
Weakened brush spring. Replace.
Burnt commutator. Replace armature. Commutator inspection.
Shorted or open winding in armature. Replace. Armature inspection.
Excessive friction in engine. Repair.
Starter motor running but Insufficient contact of starter motor relay Replace starter motor relay. Starter motor relay
too slow. (Low torque) contacts. inspection.
(If battery and wiring are Shorted armature. Replace. Armature inspection.
satisfactory, inspect Dirty or corroded commutator. Repair commutator or replace armature.
starting motor.) Armature inspection.
Worn brushes. Replace brushes.
Weakened brush spring. Replace.
Starter motor running, but Worn pinion tip. Replace pinion.
not cranking engine. Poor sliding pinion. Replace.
Worn teeth of ring gear. Replace flywheel.
Starter motor does not Broken contact point of starter motor Replace starter motor relay.
stop running. relay.
Short-circuit starter motor relay coil. Replace starter motor relay.
1I-4 Starting System:

Starter System Troubleshooting

CENFL3121904002
! CAUTION
Failure to take proper precaution when starter system troubleshooting may result in personal injury
and/or damage to electronic components.

If any abnormality is found, immediately disconnect battery cables from the battery.

NOTE
Before troubleshooting the electric starter system, make sure of the following:
• Battery is fully charged.
• All cables/wires are securely connected.
• Shift is in “Neutral” position.
• Fuse is not blown.

Circuit check schematic for tiller handle models

4
30 A
3
W/R W/R R
Br Br

6 5
8
7 Br
R/W
G Bl/W
Y/G G
Br B

2 1

BATT
IFL311190003-03
 Starting System: 1I-5

Starter Motor will Not Run Step 5

Step 1 1) Disconnect starter motor relay lead wire connector
(5).
1) Measure voltage at starter motor relay terminal
(1). 2) Measure the voltage between “Br” lead wire
terminal (6) and body ground with starter button
Is voltage 12 V (battery voltage)? (3) depressed.
Yes Go to Step 2 Is voltage 12 V (battery voltage)?
No Battery cable failure. Yes Go to step 6.

Step 2 No • Faulty starter button.

1) Measure voltage at starter relay terminal (2) with • Open “Br” lead wire circuit between
starter button (3) depressed. starter motor relay and starter button.
Is voltage 12 V (battery voltage)? Step 6
Yes Go to step 3. 1) Connect starter motor relay lead wire connector
(5) to engine main harness.
No Go to step 4.
2) Disconnect neutral switch lead wire connector (7).
Step 3 3) Measure voltage between “Y/G” lead wire terminal
1) Measure voltage at starter motor terminal (4) with (8) and body ground with starter button (3)
starter button (3) depressed. depressed.

Is voltage 12 V (battery voltage)? Is voltage 12 V (battery voltage)?

Yes Starter motor failure. Yes Go to step 7.

No Sub-battery cable failure. No • Faulty starter motor relay.

• Open “Y/G” lead wire circuit between
Step 4 starter motor relay and neutral switch
1) Check for starter motor relay “click” sound when connector.
starter button (3) depressed.
Step 7
Is a “click” sound heard?
1) Inspect neutral switch (9).
Yes Poor contacting action of starter motor Refer to “Neutral Switch Inspection” (Page 1I-17).
relay. Is result OK?
No Go to step 5. Yes Intermittent trouble or poor harness lead
wire connection.

No • Faulty neutral switch.

• Poor switch lead wire connection.
1I-6 Starting System:

Circuit check schematic for remote control models

6 Br G

5
R/W Bl/W

R
R
4
BATT
2 1

8 7

Y/G G
PUSH FREE ST IG OFF B Br
3
GND B
30 A
STOP G
BATT W
IG Gr
9
START Br
B.Z
RESET O
W W R
PUSH TURN
Br Br Br
G G Bl/O
Gr Gr Gr
B B B 10 A

IFL311190004-05
 Starting System: 1I-7

Starter Motor will not Run Step 5

Step 1 1) Disconnect starter motor relay lead wire connector
(5).
1) Measure voltage at starter motor relay terminal
(1). 2) Measure the voltage between “Br” lead wire
terminal (6) and body ground when turning ignition
Is the voltage 12 V (battery voltage)? switch (3) to “START”.
Yes Go to Step 2. Is the voltage 12 V (battery voltage)?
No Battery cable failure. Yes Go to Step 6.

Step 2 No • Faulty ignition switch.

1) Measure the voltage at starter motor relay • Open “Br” lead wire circuit between
terminal (2) when turning ignition switch (3) to starter motor relay and ignition switch.
“START”.
Step 6
Is the voltage 12 V (battery voltage)?
1) Connect starter motor relay lead wire connector
Yes Go to Step 3. (5) to engine main harness.
2) Disconnect neutral switch lead wire connector (7).
No Go to Step 4.
3) Measure the voltage between “Y/G” lead wire
Step 3 terminal (8) and body ground when turning ignition
1) Measure voltage at starter motor terminal (4) switch (3) to “START”.
when turning ignition switch to “START”. Is the voltage 12 V (battery voltage)?
Is the voltage 12 V (battery voltage)? Yes Go to Step 7.
Yes Starter motor failure. No • Faulty starter motor relay.
No Sub-battery cable failure. • Open “Y/G” lead wire circuit between
starter motor relay and neutral switch
Step 4 connector.
1) Check for starter motor relay “click” sound when
turning ignition switch (3) to “START”. Step 7
1) Inspect neutral switch (9).
Is a “click” sound heard?
Refer to “Neutral Switch Inspection” (Page 1I-17).
Yes Poor contacting action of starter motor Is result OK?
relay.
Yes Intermittent trouble or poor harness lead
No Go to Step 5. wire connection.

No • Faulty neutral switch.

• Poor switch lead wire connection.
1I-8 Starting System:

Service Instructions
Starter Motor Removal and Installation 5) Remove the bolt (5) securing starter motor band (6)
CENFL3121906001 and negative battery cable.
Removal

NOTICE
If the 12 V electrical system is shorted while
servicing the starter motor, the engine 6
electrical circuits could be damaged
seriously.

Prior to removing starter motor, disconnect

the battery cables at the battery. 5

1) Disconnect battery cables from battery.

2) Remove lower side cover. IFL311190023-02

Refer to “Lower Side Cover Removal and 6) Remove the two bolts (7) securing starter motor (8).
Installation” in Section 2A (Page 2A-3).
3) Remove the recoil starter (1) and air cleaner element 7
case (2).
Refer to “Recoil Starter Removal and Installation” in
Section 1J (Page 1J-3).

8
IFL311190024-01

7) Remove the starter motor (8).

IFL311190021-01

4) Remove the nut (3) and starter motor sub-cable (4).

4
8

IFL311190025-01

IFL311190022-01
 Starting System: 1I-9

Installation
Installation is in the reverse order of removal with special
attention to the following steps.
• Install the starter motor and tighten starter motor
mounting bolts securely.
Tightening torque
Starter motor mounting bolt (a): 23 N·m (2.3 kgf-
m, 16.5 lbf-ft)
(b)
Starter motor band (b): 11 N·m (1.1 kgf-m, 8.0 lbf-
ft)

IFL311190027-03

• Install the air cleaner element case and recoil starter.

Refer to “Air Cleaner Element Removal and
Installation” in Section 1D (Page 1D-2) and “Recoil
Starter Removal and Installation” in Section 1J (Page
1J-3).
• Check to ensure that all removed parts are back in
place.
(a)

IFL311190026-01

Starter Motor Components

CENFL3121906002

10
11 8 7 6

15
16
17
18
19 4 3 2 1
20
21
5
24
25

12 (a) 13 14

26 22 23
27 9
IFL311190005-03

1. Stopper ring 9. Stator 17. Nut 25. Brush

2. Pinion stopper 10. Armature 18. Washer 26. Brush spring
3. Spring 11. Washer 19. Washer 27. Rear cover
4. Pinion 12. Bolt 20. Washer : 4 N⋅m (0.4 kgf-m, 3.0 lbf-ft)
5. Front cover 13. Washer 21. O-ring : Apply grease.
6. Washer 14. Washer 22. Brush holder
7. Shim 15. Nut 23. Screw
8. Washer 16. Washer 24. Brush
1I-10 Starting System:

Starter Motor Disassembly and Assembly 2) Remove the bolts (12).

CENFL3121906003
Disassembly 3) Remove the front cover (5), washer (6), shim (7),
When overhauling the starting motor, it is recommended and washer (8).
that the component parts be cleaned thoroughly. 4) Remove the stator (9), armature (10) and washer
However, the stator assembly, armature coil, pinion and (11).
rubber or plastic parts should not be washed in a
degreasing tank or with a grease dissolving solvent.
These parts should be cleaned with compressed air or 5
wiped with clean cloth.

NOTE 6 9
For correct assembly, scribe an alignment 7
mark on each part of starter motor. 8

10

IFL311190028-02 11

! WARNING
Failure to take proper precautions when
removing stopper ring can cause personal 12
injury.

Wear safety glasses when disassembling and IFL311190007-02

assembling the stopper ring.
5) Remove the nut (13), washer (14) (15), plastic
washer (16) and O-ring (17) from rear cover (18).
NOTE
6) Remove the two screws (19) and brush holder
Using a screw-driver, pry off the stopper ring. assembly (20).

1) Push the pinion stopper (2) down, then remove the 19

stopper ring (1). Remove the pinion stopper, spring
(3) and pinion (4).
20
1
2

3 16 17
15
14
13 18
4

IFL311190008-02

IFL311190006-02
 Starting System: 1I-11

Assembly • Align the notch in the front and rear cover with the tab
Assembly is in the reverse order of disassembly with on the stator when assembling.
special attention to the following steps. • Tighten the through bolts securely.
Reassemble the starter motor, refer to “Starter Motor
Components” (Page 1I-9). Tightening torque
Bolt (a): 4 N·m (0.4 kgf-m, 3.0 lbf-ft)
• When installing the armature, use care to avoid
breaking the brushes.
• Apply grease to armature shaft and shaft holes.
(a)
: Grease 99000–25011 (SUZUKI Super Grease
A (450 g))

IFL311190010-03

• Install the pinion (1), spring (2), pinion stopper (3) and
stopper ring (4).

NOTE
Make sure stopper ring (4) fit tightly in pinion
stopper (3) and armature shaft (5).

4
3 5
4
2
3

IFL311190011-02

IFL311190009-01
1I-12 Starting System:

Starter Motor Components Inspection and • Check that the mica (insulator) between the segments
Servicing is undercut to specified depth.
CENFL3121906004 If the measurement exceeds the service limit, cut to
Pinion the specified depth.
Inspect pinion.
Replace pinion if damage or worn. ! WARNING
Failure to following proper precautions
during use of the compressed air may cause
severe personal injury.

Wear safety glasses when using compressed

air.

NOTE
IFL311190012-01
Remove all particles of mica and metal using
Armature and Commutator compressed air.
• Inspect the commutator surface. If surface is gummy Commutator undercut “a”
or dirty, clean with # 500 grit emery paper (1). Standard: 0.5 – 0.8 mm (0.02 – 0.03 in.)
Service limit: 0.2 mm (0.01 in.)

“a”

1 2
IFL311190013-01 I9J011190024-01

• Measure the commutator outside diameter. If the 2. Mica 3. Segment

measurement exceeds the service limit, replace the
armature. • Check for continuity between the commutator (4) and
the armature core (5) / shaft (6).
Special tool
Replace the armature if continuity is indicated.
(A): 09900–20101 (Vernier calipers (150
mm)) Special tool
: 09900–25008 (Multi circuit tester set)
Commutator outside diameter
Standard: 30 mm (1.18 in.) Tester knob indication
Service limit: 29.0 mm (1.14 in.) Continuity ( )

5
4
6

(A)

IFL311190014-02
IFL311190015-01
 Starting System: 1I-13

• Check for continuity between adjacent commutator Brush Holder

segments. Replace armature if no continuity is Check brush holder continuity.
indicated. Replace the brush holder if the tester doesn't show the
below.
Tester knob indication
Continuity ( ) Special tool
: 09900–25008 (Multi circuit tester set)
Tester knob indication
Continuity ( )
Brush holder continuity
Continuity
Brush holder positive (+) to brush
No
holder negative (–)
Brush holder positive (+) to base
No
plate (ground)
IFL311190016-01

Brushes
Check the length of each brush (1).
If brushes are worn down to the service limit, they must
be replaced.
Special tool
(A): 09900–20101 (Vernier calipers (150 mm))
Brush length
Standard: 12.5 mm (0.49 in.)
Service limit: 9.0 mm (0.35 in.) 1
IFL311190017-02
(A)
1. Base plate

I9J011190027-01
1I-14 Starting System:

Starter Motor Relay Inspection 6) Check continuity between terminal (7) and (8) each
CENFL3121906005 time 12 V power supply is applied to terminal (9) and
Inspect the starter motor relay using the following (10).
procedures: Connect the positive (+) lead to terminal (9), and
! CAUTION negative (–) lead to terminal (10).

Failure to take proper precaution when NOTICE

removing electrical parts may result in If the 12 V power supply wire is connected to
personal injury and/or damage to electronic wrong terminal or touched to each other, the
components. power supply wire, tester may be damaged.

Prior to removing electrical parts, disconnect Be careful not to touch 12 V power supply
battery cables from battery. wires to each other or with other terminals.

1) Disconnect battery cables from battery. Special tool

2) Remove the bolt (1) and starter motor sub-cable (2). (A): 09900–25008 (Multi circuit tester set)
3) Remove the bolt (3) and battery cable (4). Tester knob indication
4) Disconnect starter motor relay lead wire connector Continuity ( )
(5). Starter motor relay function
Continuity
5 12 V power applied Yes
2 12 V power not applied No

8
7
3

1
4

IFL311190029-02

5) Pull out the starter motor relay (6) from electric parts
holder. 10 9

CONT

6 (A)
12 V
IFL311190019-02

IFL311190030-01
 Starting System: 1I-15

7) Measure the resistance between relay wiring leads 2) Remove the snap ring (1) from clutch shaft, then
(9) and (10). account for washer (2), spring (3) and notch ball (4).
If out of specification, replace starter motor relay.
Tester knob indication
Resistance (Ω)
Starter motor relay coil resistance
Standard: 4.2 – 4.6 Ω

4
1 2 3
IFL311190033-02

3) Remove the bolt (5) securing clutch rod arm.

10 9

(A) 5
IFL311190020-02

8) Reinstall parts removed earlier.

IFL311190034-01

Neutral Switch Removal and Installation 4) Using a punch, remove the pin (6).
CENFL3121906006
Removal
1) Remove the clutch shaft holder (with clutch rod and
clutch shaft).
Refer to “Power Unit Removal and Installation” in
Section 1D (Page 1D-15).

IFL311190035-01

5) Remove the clutch shaft (7) and washer (8).

IFL311190032-01

7
8

IFL311190036-01
1I-16 Starting System:

6) Remove the screws (9) and notch plate (10). 10) Remove the E-ring (15) and remove the clutch rod
(16) from clutch rod arm (17).

15

16 17

10

IFL311190037-01

7) Remove the switch push rod (11). IFL311190041-01

Installation
Installation is reverse order of removal with special
attention to the following steps.
• Place the clutch rod arm (1) (with clutch rod (2)) to
clutch shaft holder (3).

1
11 3

IFL311190038-01

8) Remove the screws (12) and neutral switch (13).

2
13
IFL311190042-01

• Install the neutral switch (4), and secure it with screws

(5).
Apply thread lock to screws (5) before threading.
12
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))

IFL311190039-01

9) Remove the clutch rod arm (14) from clutch shaft

holder. 4

14 5

IFL311190043-01

IFL311190040-01
 Starting System: 1I-17

• Install the switch push rod (6) and notch plate (7), • Install the clutch shaft holder (with clutch rod and
then securely tighten it with screws (8). clutch shaft).
Refer to “Power Unit Removal and Installation” in
Section 1D (Page 1D-15).

Neutral Switch Inspection

CENFL3121906007
Check for continuity / infinity of the neutral switch.
Special tool
(A): 09900–25008 (Multi circuit tester set)
6
Tester knob indication
7 Continuity ( )
8
IFL311190044-02 1) Disconnect the neutral switch lead wire connector.
• Place the washer (9) into position, then insert the 2) Check continuity / infinity between the Yellow / Green
clutch shaft (10) through clutch shaft holder and clutch and Brown lead wires while operating the shift lever.
rod arm.
Neutral switch function
Shift position Tester indicates
Neutral Continuity
Forward Infinity
Reverse Infinity

9 10

IFL311190045-02

• Tighten the bolt (11) securely.

• Install the pin (12).

IFL311190031-01

(A)

Y/G
12
11

Br
IFL311190046-02

• Install the notch ball (13) and spring (14).

Install the washer (15) and snap ring (16). I9J011190047-03

3) If out of specification:
• 1st:
Check switch position adjustment, readjust if
necessary.
• 2nd:
Replace the neutral switch and recheck.

NOTE
After installing the neutral switch, check for
13 correct function by operating the shift lever.
15 14 16
IFL311190047-03
1I-18 Starting System:

Starter Button Inspection Ignition Switch Inspection

CENFL3121906008 CENFL3121906009
1) Disconnect the starter button lead wire connector. Inspect the ignition switch using the following
procedures:
2) Check the continuity / infinity between the wiring
leads under the condition shown below. 1) Disconnect the ignition switch from remo-con box
wiring harness.
Special tool
2) Check continuity between wiring leads at the key
(A): 09900–25008 (Multi circuit tester set)
positions shown in the chart.
Tester knob indication 3) If out of specification, replace the ignition switch.
Continuity ( )
Special tool
Tester probe connection Tester
: 09900–25008 (Multi circuit tester set)
Red (+) Black (–) indicates
Starter button Tester knob indication
Infinity
not depressed Continuity ( )
W/R Br
Starter button
Continuity
depressed
Switch Lead Wires
Key position
B G W Gr Br O
OFF
ON

Br W/R START
(A) FREE
PUSH
IDK111190008-01 : Continuity
I9J011190041-03
3) If out of specifications, replace the starter button.

(OFF) (ON)
FREE
(START)

PUSH

O
Br
B
W

Bl
Gr
G
B G
Bl
Gr
IDK112190001-01
 Manual Starting System: 1J-1

Manual Starting System

Power Head

Precautions
Precaution for Manual Starting System
CENFL3121A00001
! CAUTION
Failure to take proper precautions when servicing the recoil starter can cause personal injury.

Wear safety glasses and hand protection when winding or unwinding this component.

General Description
Manual Starting System
CENFL3121A01001
The manual starter engages the flywheel ratchet with one pawl when the starter grip is pulled.
A recoil spring is wound as the starter rope pulls and rewinds as the starter grip is returned to the case.
The NSI set linked to the clutch rod arm prevents accidental manual starter engagement while the motor is in gear.

4
IFL3111A0016-04

1. Recoil starter 3. Clutch lever shaft 5. NSI set

2. NSI cable 4. Clutch rod arm
1J-2 Manual Starting System:

Service Instructions
Recoil Starter Components
CENFL3121A06001

3
4

5
6

1
7 2

21

20

11

19

10

12

15 13
14 16

17

18
IFL3111A0017-02

1. NSI cable 7. Reel stopper 13. Ratchet 19. Bolt

2. Recoil starter case 8. Recoil spring 14. Ratchet guide 20. Seal
3. Cotter pin 9. Reel 15. Return spring 21. Seal
4. Washer 10. Rope 16. Friction spring : Apply thread lock 1342.
5. Stopper arm 11. Grip 17. Friction plate : Apply water resistant grease.
6. Spring 12. Screw 18. Screw
 Manual Starting System: 1J-3

Recoil Starter Removal and Installation 4) Loosen the lock nuts (6) and remove NSI cable (7)
CENFL3121A06002 from cable bracket (8).
Removal
1) On the electric starter model:
Remove the air cleaner element case (1). 7
Refer to “Air Cleaner Element Removal and
Installation” in Section 1D (Page 1D-2).

8
6
1

IFL3111A0006-01

5) Remove the NSI cable from NSI lever (9).

IFL3111A0002-01

2) Remove the two bolts (2) and air intake duct (3).

IFL3111A0007-01

6) Remove the bolt (10) securing cam pulley cover (11).

3

11
IFL3111A0003-01

3) On the electric starter model:

Remove the two bolts (4) securing air intake silencer
case (5), then slightly rotate the intake silencer case
counterclockwise.

NOTE
Do not remove the intake silencer case from
10
throttle body but just rotate it this time.
IFL3111A0008-01
The IAC hose and the breather hose are
connected to the intake silencer case so that 7) Loosen the three bolts (12) securing recoil starter
it is quite difficult to reassemble them if the (13).
silencer case is removed. Remove the recoil starter.

12
4
13

IFL3111A0009-02

IFL3111A0005-03
1J-4 Manual Starting System:

Installation 2) Remove the screw (2), then remove the friction plate
Installation is in the reverse order of removal with special (3) with the friction spring (4).
attention to the following. 3) Remove the reel (1).
• Tighten the silencer case bolt securely.
• Check to ensure that all removed parts are back in
3 4
place. 2
• Check the neutral start interlock function.
Refer to “NSI Cable Installation and Adjustment”
(Page 1J-8).
• Wire and hose routing matches service manual
illustration.
Refer to “Wiring Harness Routing Diagram” in Section 1
4A (Page 4A-7) and “Fuel/Water Hose Routing” in
Section 4B (Page 4B-1).
IDK1111A0005-01

4) Remove the screw (5) first, and then take off the
ratchet (pawl) (6), ratchet guide (7) and return spring
(8).

IFL3111A0010-01

Recoil Starter Disassembly and Assembly

CENFL3121A06003
! CAUTION IDK1111A0006-02

Failure to take proper precautions when

servicing the recoil starter can cause
personal injury. 6

Wear safety glasses and hand protection

when winding or unwinding this component.

Disassembly
7
1) Pull the rope out of recoil case and guide the rope
into notch “A” in the reel (1), then turn the reel 8
clockwise to release the coiled tension in the recoil
spring. IDK1111A0008-01

5) Remove the recoil rope (9).

9
A

IFL3111A0011-02
IDK1111A0007-01
 Manual Starting System: 1J-5

NOTE Assembly
Do not remove the recoil spring unless Reassembly is in the reverse order of disassembly with
replacement is necessary. special attention to the following reassembling step.
It should be visually inspected in its • Install the reel stopper (1).
assembled position.

6) Remove the recoil spring (10).

10

IDK1111A0025-01

• Install the stopper spring (2) as shown in figure.

IDK1111A0009-01

7) Remove the NSI cable (11) with spring (12).

2
Remove the cotter pin (13), washer (14) and stopper
arm (15).

11
12

IDK1111A0012-01
15
• Install NSI set and NSI cable (3).
Apply grease to NSI cable.
14 : Grease 99000–25350 (SUZUKI Water
13
IFL3111A0012-01
Resistant Grease EP2 (250 g))
8) Remove the reel stopper spring (16) and reel
stopper (17).

17
16
IFL3111A0013-01

IDK1111A0011-01
1J-6 Manual Starting System:

• Secure the outer end “A” of recoil spring (4) on groove • Install the reel (8) on the recoil case.
“B” in recoil case and wind spring inward towards
center of case in a counterclockwise direction. NOTE
• Apply grease to reel as shown figure.
• Align groove “C” in the reel with bent end
4 “D” of recoil spring.

“B” : Grease 99000–25350 (SUZUKI Water

“A” Resistant Grease EP2 (250 g))

“C”

IDK1111A0014-01

• Install the recoil rope (5).

5
“D”
IFL3111A0015-01

• Install the friction plate (9) (with friction spring (10))

and secure it with screw (11).
Apply thread lock 1342 to screw (11) before threading.
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
IDK1111A0015-01 NOTE
• Install the ratchet set (6), then tighten ratchet with Twist friction plate slightly to align holes “E”
screw (7). in plate with square lugs “F” on center boss.
Apply thread lock 1342 to screw (7) before threading.

10
9
11

“E”

6 “F”

IDK1111A0016-01 IDK1111A0019-01

• After assembling, guide the rope into notch in the reel

and rotate the reel approximately 5 turns
counterclockwise until the spring is tensioned.

IDK1111A0026-01

IFL3111A0014-01
 Manual Starting System: 1J-7

Recoil Starter Components Cleaning and • Inspect the recoil rope.

Inspection If the recoil rope is worn or damaged, replace it.
CENFL3121A06004
NOTE
If any parts is worn excessively, cracked,
defective or damaged in any way, it must be
replaced.

• Wash metal components in cleaning solvent and dry

with compressed air before inspection.
• Inspect the ratchet (pawl), stopper arm and all
springs.
If there is any defect such as excessive wear or
damage, replace it. IDK1111A0023-01

• Inspect the recoil spring.

If there is any cracks, deformation or excessive curve
on the recoil spring, replace it.

IDK1111A0021-01

• Inspect the reel and recoil case.

If any cracks or damage is found on them, replace it.
IDK1111A0024-01

IDK1111A0022-01
1J-8 Manual Starting System:

NSI Cable Installation and Adjustment 1) Shift into “Neutral” position.

CENFL3121A06005
2) Install the NSI cable (1) in the recoil starter (2), the
“B” NSI lever (clutch rod arm) (3), the stopper arm (4)
and the cable bracket (5).
“A”
3) Turn the adjustment nut (6) to align the slot “A” on
4 the stopper arm (4) with the punch mark “B” on the
recoil starter case.
4) Pull the recoil starter grip and make sure that the
starter does not work when the shift lever is in
1 “Forward” and “Reverse” position.
6
5) Tighten the lock nuts (7).
2 6) Apply water resistant grease to inner cable, the
5
7 cable end and cable holding area.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))

! WARNING
If the NSI cable is removed or left without
3 correct adjustment, there is a high risk of
losing one’s balance and/or being thrown
overboard if the motor starts in gear.

Do not operate the motor when the NSI cable

is detached or the adjustment is not correctly
IFL3111A0001-02
done.
 Charging System: 1K-1

Charging System
Power Head

General Description
Charging System Description
CENFL3121B01001
The battery charging system circuit is illustrated below.
It is composed of the battery charge coil, rectifier/regulator and battery. The three phase AC current generated from
the battery charge coil is converted by the rectifier/regulator into regulated DC current which is used to charge the
battery.
Battery charge coil output
Standard: 12 V 14 A (168 W) at 5 000 r/min
Regulated voltage
Standard: 14.5 – 15.2 V

Electric Starter Model

W W
W W
4 W W
2
R R/Y To ECM
B

Y 3
Y
Y
W R
5
B

R
6
B 8 7

+ –
M R R R

R/W Br
9
B/W G
To neutral switch
IFL3111B0001-04

1. Flywheel 4. Rectifier/regulator No.1 7. Starter motor relay

2. ECM power source coil 5. Rectifier/regulator No.2 8. Starter motor
3. Battery charge coil 6. Fuse (30 A) 9. Battery

Battery Requirement Description

CENFL3121B01002
Refer to “Battery Requirement” in Section 0A (Page 0A-6).
1K-2 Charging System:

Component Location
Charging System Components Location
CENFL3121B03001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-7).

Diagnostic Information and Procedures

Charging System Diagnosis
CENFL3121B04001

Condition Possible cause Correction / Reference Item

Alternator (Battery charge Open or short circuit lead wires. Repair or replace.
coil) does not charge. Open or short circuit battery charge coil. Replace.
Rectifier/Regulator failure. Replace.
Main fuse blown out. Replace.
Poor or broken battery connection. Repair or replace.
Alternator (Battery charge Rectifier/Regulator failure. Replace.
coil) overcharge. Poorly grounded rectifier/regulator. Repair or retighten.
Unstable charging Short circuit battery charge coil. Replace.
Loose lead wire connection. Repair or replace.
Rectifier/Regulator failure. Replace.
Poor or broken battery connection. Repair or replace.
 Charging System: 1K-3

Service Instructions
Charging System Construction
CENFL3121B06001

1 (a)

2
3

4
5

12

10
11
9

13

15

14

IFL3111B0024-01

1. Nut 10. Fuse (30 A) (Except for manual starter model)

2. Washer 11. Fuse case (Yellow) (Remote control model)
3. Key 12. Fuse (10 A) (Remote control model)
4. Flywheel (Manual starter model) 13. Rectifier/regulator No.1
5. Flywheel (Electric starter model) 14. Rectifier/regulator No.2
6. ECM power source coil/Battery charge coil 15. Bracket
7. Screw : 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft)
8. Wiring harness assembly : Apply SUZUKI Bond 1207B.
9. Fuse case (White) (Except for manual starter model)
1K-4 Charging System:

Flywheel Removal and Installation 4) Remove the flywheel nut (1), washer (2), flywheel (3)
CENFL3121B06002 and key (4).
Removal

! CAUTION
1
Failure to take proper precaution when 2
removing flywheel may result in personal 4
injury and/or damage to electronic
components.
3
Prior to removing flywheel, disconnect
battery cables from battery.

1) Remove the recoil starter.

IFL3111B0026-02
Refer to “Recoil Starter Removal and Installation” in
Section 1J (Page 1J-3).
Installation
2) Using special tool, loosen flywheel nut 2 – 3 turns. Installation is reverse order of removal with special
NOTE attention to the following steps.
• Clean flywheel and crankshaft mating surfaces with
Do not remove flywheel nut at this time.
cleaning solvent.
This nut prevents damage to the crankshaft
when using flywheel remover tools.

Special tool
(A): 09930–48720 (Flywheel holder)
(B): 09930–49211 (Flywheel holder
attachment)

(A)
(B)

IFL3111B0025-01

• Tighten flywheel nut to specified torque.

Special tool
IFL3111B0007-01
(A): 09930–48720 (Flywheel holder)
3) Using special tools, loosen flywheel from crankshaft. (B): 09930–49211 (Flywheel holder
Special tool attachment)
(C): 09930–39411 (Flywheel remover) Tightening torque
(D): 09930–39420 (Flywheel remover bolts) Flywheel nut (a): 100 N·m (10.0 kgf-m, 72.5 lbf-ft)

(D) (B)
(A)
(C)

(a)

IFL3111B0008-02 IFL3111B0009-02
 Charging System: 1K-5

• After installing flywheel and torquing nut to 3) Disconnect lead wire connector from ECM (1).
specification, check air gap between CKP sensor and Remove ECM from electric part holder.
flywheel reluctor bars.
CKP sensor air gap “a”
1.0 mm (0.04 in) 1

2
3

“a”
1

1 IFL3111B0011-01

4) Disconnect lead wire connector (2) at rectifier/

regulator No.2.
IFL3111B0010-02
Remove the bolt (3) securing the GND lead wire.
1. CKP sensor 3. Thickness gauge
2. Flywheel reluctor bar
3

Final Assembly Check

All parts removed have been returned to their original
position.

Battery Charge Coil Removal and Installation

CENFL3121B06003
2
! CAUTION
Failure to take proper precaution when
IFL3111B0012-01
removing electrical parts may result in
5) Disconnect lead wire connector (4) from rectifier/
personal injury and/or damage to electronic
regulator No.1.
components.
Remove the cable tie binding lead wires.
Prior to removing electrical parts, disconnect
battery cables from battery.

NOTE
4
Motor depicted is electric starter model.

Removal
1) Remove both lower side covers.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
2) Remove flywheel. IFL3111B0013-01
Refer to “Flywheel Removal and Installation” (Page
1K-4).
1K-6 Charging System:

6) Remove the three screws securing battery charge • Check that coil lead wires are routed properly and
coil (5). away from hot or rotating parts.
Cut the cable tie securing battery charge coil lead For wire routing, refer to “Wiring Harness Routing
wire to electric parts holder. Diagram” in Section 4A (Page 4A-7).
Remove the battery charge coil. • Install flywheel and tighten flywheel nut to specified
torque.
Refer to “Flywheel Removal and Installation” (Page
5 1K-4).

Battery Charge Coil Inspection

CENFL3121B06004
Measure battery charge coil resistance in the following
procedure.
1) Disconnect battery charge coil leads from rectifier/
regulator No.2.
2) Measure resistance between leads in the
IFL3111B0014-01 combinations shown.
If measurement exceeds specification, replace
Installation battery charge coil.
Installation is reverse order of removal with special
attention to the following steps. Special tool
: 09900–25008 (Multi circuit tester set)
• Apply SUZUKI Bond 1207B to the coil securing bolts.
Tester knob indication
: Sealant 99000–31140 (SUZUKI Bond
Resistance (Ω)
1207B (100 g))
Battery charge coil resistance
• Install battery charge coil, then tighten bolts securely.
Terminal for tester probe connection Resistance
Y1 to Y2
Y2 to Y3 0.4 – 0.6 Ω
Y3 to Y1

IFL3111B0015-02

• Secure the battery charge coil lead wire to the electric

parts holder with cable tie.

Y1 Y2 Y3
IFL3111B0002-04

IFL3111B0016-01
 Charging System: 1K-7

ECM Power Source Coil Inspection Rectifier / Regulator Removal and Installation
CENFL3121B06005 CENFL3121B06006
Measure ECM power source coil resistance in the Removal
following procedure.
! CAUTION
1) Disconnect ECM power source coil leads from
rectifier/regulator No.1. Failure to take proper precaution when
2) Measure resistance between leads in the removing electrical parts may result in
combinations shown. personal injury and/or damage to electronic
If measurement exceeds specification, replace ECM components.
power source coil.
Prior to removing electrical parts, disconnect
Special tool battery cables from battery.
: 09900–25008 (Multi circuit tester set)
Tester knob indication NOTE
Resistance (Ω) Motor depicted is electric starter model.
ECM power source coil resistance
1) Remove the lower side covers.
Terminal for tester probe connection Resistance
Refer to “Lower Side Cover Removal and
W1 to W2
Installation” in Section 2A (Page 2A-3).
W2 to W3 1.1 – 1.7 Ω
W3 to W1 2) Disconnect battery charge coil lead wire connector
at rectifier/regulator No.2.
3) Remove the bolts and rectifier/regulator No.2 (1).

W1
W2
W3 1

IFL3111B0006-01
IFL3111B0017-01

4) Disconnect battery charge coil lead wire connector

from rectifier/regulator No.1 (2).
Disconnect charge output (R) lead wire from rectifier/
regulator No.1.

IFL3111B0018-02
1K-8 Charging System:

5) Remove the bolts and rectifier/regulator No.1 (2).

IFL3111B0019-01

Installation
Installation is reverse order of removal with special
attention to the following steps.
• Install rectifier/regulator No.1 (1), then tighten bolts (2)
securely.

IFL3111B0020-01

• Install rectifier/regulator No.2 (3), then tighten bolts (4)

securely.

3
4

IFL3111B0021-02

• Connect lead wire connector to rectifier/regulator.

Check that lead wire routed properly.
Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-7).
• Install lower side covers.
Refer to “Lower Side Cover Removal and Installation”
in Section 2A (Page 2A-3).
 Charging System: 1K-9

Rectifier / Regulator Inspection

CENFL3121B06007
Inspect the rectifier/regulator in the following procedures:
1) Remove the rectifier/regulator No.1 and No.2.
Refer to “Rectifier / Regulator Removal and Installation” (Page 1K-7).
2) Measure voltage between leads in the combinations shown.
If measurement exceeds specification, replace rectifier/regulator.
Special tool
: 09900–25008 (Multi circuit tester set)
Tester knob indication
Diode test ( )

Rectifier/regulator No.2 (for battery charging)

W B

Y1 Y2 Y3
IFL3111B0004-04

Unit: V
Tester probe (+)
W B Y1 Y2 Y3
W — 0.4 – 0.7 0.3 – 0.6 0.3 – 0.6 0.3 – 0.6
B * — * * *
Tester probe (–) Y1 * 0.3 – 0.6 — * *
Y2 * 0.3 – 0.6 * — *
Y3 * 0.3 – 0.6 * * —
*: 1.4 V or more (Tester’s battery voltage.)

Rectifier/regulator No.1 (for ECM power)

B
W1
W2
W3
R

IFL3111B0003-04

Unit: V
Tester probe (+)
R B W1 W2 W3
R — 0.4 – 0.7 0.3 – 0.6 0.3 – 0.6 0.3 – 0.6
B * — * * *
Tester probe (–) W1 * 0.3 – 0.6 — * *
W2 * 0.3 – 0.6 * — *
W3 * 0.3 – 0.6 * * —
*: 1.4 V or more (Tester’s battery voltage.)

NOTE
If the tester reads 1.4 V or below when the tester probes are not connected, replace its battery.
1K-10 Charging System:

3) Install the rectifier/regulator No.1 and No.2.

Refer to “Rectifier / Regulator Removal and Installation” (Page 1K-7).

Fuse Inspection
CENFL3121B06008
Inspect the fuse in the following procedures.
1) Remove the fuse from fuse case.
2) Inspect continuity between both terminal of fuse.
If no continuity is indicated, replace fuse.
Special tool
: 09900–25008 (Multi circuit tester set)
Tester knob indication
Continuity ( )

“A”

IFL3111B0022-02

“B”

“A”

IFL3111B0023-01

“A”: Main fuse 30 A (White fuse case) (Except for manual starter model)
“B”: ECM fuse (Yellow fuse case) (Remote control model)

CONT

IFL3111B0005-01
 Table of Contents 2- i

Section 2

Mid Unit
CONTENTS

Precautions .................................................2-1 Clamp / Swivel / Steering Brackets Related

2
Precautions............................................................. 2-1 Components Inspection (A/AR models) ..........2A-34
Precaution for Mid Unit ......................................... 2-1 Clamp / Swivel / Steering Brackets
Components (T/Q Model)................................2A-35
Housing and Bracket............................... 2A-1 Clamp / Swivel / Steering Brackets
Precautions...........................................................2A-1 Disassembly (T/Q Model)................................2A-37
Precaution for Housing and Bracket ................... 2A-1 Clamp / Swivel / Steering Brackets Assembly
(T/Q Model) .....................................................2A-39
Service Instructions.............................................2A-2
Clamp / Swivel / Steering Brackets Related
Lower Side Cover Components .......................... 2A-2
Components Inspection (T/Q Model) ..............2A-41
Lower Side Cover Removal and Installation ....... 2A-3
Tiller Handle and Handle Bracket Removal Power Trim and Tilt ................................. 2B-1
and Installation .................................................. 2A-4
Throttle Control Cable Installation and Precautions...........................................................2B-1
Adjustment ........................................................ 2A-6 Precaution for Power Trim and Tilt......................2B-1
Steering Friction Adjuster Disassembly and General Description .............................................2B-2
Assembly .......................................................... 2A-7 Power Trim and Tilt Description ..........................2B-2
Tiller Handle Components ................................ 2A-10 Principles of Power Trim and Tilt Operation
Tiller Handle Disassembly and Assembly ......... 2A-11 Description ........................................................2B-3
Engine Holder / Driveshaft Housing / Mounts Schematic and Routing Diagram ........................2B-8
Components.................................................... 2A-13 Power Trim and Tilt System Diagram .................2B-8
Engine Holder / Driveshaft Housing / Mounts Diagnostic Information and Procedures ............2B-9
Disassembly.................................................... 2A-15 Diagnose PTT System Malfunction.....................2B-9
Engine Holder / Driveshaft Housing / Mounts Service Instructions ...........................................2B-10
Assembly ........................................................ 2A-17 Checking PTT Fluid Level .................................2B-10
Engine Holder / Driveshaft Housing / Mounts Air Bleeding from PTT Unit ...............................2B-10
Related Component Inspection....................... 2A-21 Power Trim and Tilt Unit Removal and
Driveshaft Upper Oil Seal Replacement ........... 2A-22 Installation .......................................................2B-11
Gas Cylinder Unit Removal and Installation Power Trim and Tilt Unit Components ..............2B-14
(Q Model) ........................................................ 2A-23 Power Trim and Tilt Unit Disassembly and
Gas Cylinder Related Items Inspection Reassembly ....................................................2B-15
(Q Model) ........................................................ 2A-25 Power Trim and Tilt Unit Components
Clamp / Swivel / Steering Brackets Cleaning and Inspecting..................................2B-19
Components (A/AR models) ........................... 2A-26 Power Trim and Tilt Motor Disassembly and
Clamp / Swivel / Steering Brackets Assembly.........................................................2B-20
Disassembly (A/AR models) ........................... 2A-28 PTT Motor Related Items Inspection.................2B-20
Clamp / Swivel / Steering Brackets Assembly PTT Motor Relay Inspection..............................2B-22
(A/AR models)................................................. 2A-31 PTT Switch Inspection ......................................2B-23
2-1 Precautions:

Precautions
Mid Unit

Precautions
Precaution for Mid Unit
CENFL3122000001
Refer to “General Precautions” in Section 00 (Page 00-1).
 Housing and Bracket: 2A-1

Housing and Bracket

Mid Unit

Precautions
Precaution for Housing and Bracket
CENFL3122100001
NOTICE
Do not break or cut bonding wires, as they perform an important function in the prevention of galvanic
corrosion or build up of static charges.
Replace any damaged wire.

NOTE
• When dismantling housing and bracket, inspect mountings and bolts for damage and wear. Replace
if necessary.
• Check the condition of the zinc anodes on lower section of mid unit. Replace if necessary.
2A-2 Housing and Bracket:

Service Instructions
Lower Side Cover Components
CENFL3122106001

10
11
13

1
12
21
20

14 9
22
6
16

3 (a)
15 19
7
8 (b)
17 5
18

IFL311210113-01

1. Lower side cover STBD 10. Fastener 19. Clip

2. Lower side cover PORT 11. Pin 20. Holder
3. Screw 12. Washer 21. Bolt
4. Side cover rubber 13. Clip 22. Plug
5. Side cover seal 14. Cable grommet : 5 N⋅m (0.5 kgf-m, 3.6 lbf-ft)
6. Front panel 15. Rivet : 5 N⋅m (0.5 kgf-m, 3.6 lbf-ft)
7. Cushion 16. Boot : Apply SUZUKI Silicone seal
8. Screw 17. Screw : Apply SUZUKI water resistant grease.
9. Hook 18. Cushion
 Housing and Bracket: 2A-3

Lower Side Cover Removal and Installation 4) Remove three screws (8) and PORT lower side
CENFL3122106002 cover (9).
Removal
Disconnect PTT switch lead wire connector.
1) Remove the side cover rubber (1).
8

IFL311210016-01
IFL311210014-01

2) Remove the snap pin (2), washer (3), pin (4) and
fastener (5) (if necessary).

5
4
3
2 IFL312210041-01
3
Installation
IFL311210001-02 Installation is reverse order of removal with special
3) Remove the seven screws (6) and STBD lower side attention to the following step.
cover (7).
NOTE
Before tightening the side cover screws,
6 apply an water resistant grease to the
threads of them, however apply a sealant to
the screws “A” only in two places shown in
the figure.

: Sealant 93691–80030 (SUZUKI Silicone Seal

7 (100 g))

“A”
IFL311210015-01

IFL311210017-02

• Tighten side cover screws to specified torque.

Tightening torque
Side cover screw: 5 N·m (0.5 kgf-m, 3.6 lbf-ft)
2A-4 Housing and Bracket:

Tiller Handle and Handle Bracket Removal and 4) Loosen the throttle cable lock nuts (9).
Installation
CENFL3122106003
Removal
1) Remove STBD lower side cover.
Refer to “Lower Side Cover Removal and
Installation” (Page 2A-3).
2) Disconnect the stop switch lead wire connector (1).
On the PTT model;
9
Disconnect PTT switch lead wire connector (2).
9

IFL312210045-01

5) Remove the bolt and washer securing throttle drum

(10), then remove the throttle drum and spacer.
2

IFL312210042-01

3) Loosen the bolt (3) securing shift lever (4).

Remove the bolt (3), shift lever (4), washer (5),
washer (6), wave washers (7) and spacer (8). 10

IFL312210046-01

4
6) Disconnect throttle link rod from throttle drum.
7) Remove the throttle cables (11) from throttle drum
and cable bracket (12).

12

IFL312210043-01

11
IFL312210047-01

8
4

3 5 6 7
IFL312210044-01
 Housing and Bracket: 2A-5

8) Loosen the cable clamp (13) and remove the battery Installation
cable (14) from handle bracket. Installation is reverse order of removal with special
attention to the following steps.

Tiller handle
13 • Place bushing (1), friction rubber (2) and bushing (3)
on tiller handle.
14

3
IFL312210048-01

9) Remove the bolts (15) securing handle bracket to

steering bracket.
1
Remove the tiller handle and handle bracket
assembly. 2
IFL311210026-02

• Install the tiller handle (4) and handle cover (5).

NOTE
Before installing tiller handle cover, check
that lead wire and cable routing properly.

• Tighten handle cover bolts to the specified torque.

Tightening torque
Tiller handle bolt (a): 23 N·m (2.3 kgf-m, 16.5 lbf-
15
ft)
IFL312210049-01

10) Remove the bolts (16) and cover (17) from handle
bracket. 4
Remove the bolts (18) and tiller handle cover (19).
Remove the tiller handle (20) and cable assembly.

(a)
IFL311210027-02
17
16
IFL312210050-01

19

20 18
IFL312210051-01
2A-6 Housing and Bracket:

Handle bracket Throttle Control Cable Installation and

• Install the handle bracket and tiller handle assembly Adjustment
CENFL3122106004
(1).
1) Turn the throttle control grip its completely closed
• Tighten handle bracket bolt, pre-coated with thread
position.
lock, to the specified torque.
2) Fit two throttle control cables, (1) and (2) both to the
Tightening torque throttle drum (3) and cable holder (4).
Tiller handle bracket bolt (a): 23 N·m (2.3 kgf-m,
16.5 lbf-ft)
1
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))

2
4

3
1
IFL311210030-01

3) Place the throttle drum into position, then securely

(a)
tighten it with bolt.

IFL311210028-03

Throttle cables
• Install the throttle cables (1) to throttle drum (2) and
cable bracket (3).
• Place the throttle drum into position, then securely
tighten it with bolt.
• Adjust of throttle control cable.
Refer to “Throttle Control Cable Installation and
Adjustment” (Page 2A-6).
IFL311210031-02

4) Temporarily tighten the cable lock nut (5) and (6).

5) Check cable for tension.
If cable is too tight or too loose, adjust it by adjusting
1
lock nut.
6) Secure the throttle control cable (1) and (2) on the
cable holder by tightening lock nuts.

2 3

1
IFL311210029-02

Final assembly check

• Perform the following final assembly checks to ensure
5
proper and safe operation of the repaired unit. 6 2
– All parts removed have been returned to their
original positions.
IFL311210032-02
– Wire routing matches service manual illustration.
Refer to “Wiring Harness Routing Diagram” in
Section 4A (Page 4A-7).
 Housing and Bracket: 2A-7

7) Make sure the clearance “a” exists between the lever 3) Remove the two bolts (2) securing steering adjuster
“A” and the stopper “B” with throttle control fully plate (3).
opened. Remove the two bolts (4) securing steering adjuster
If not, adjust again. base plate (5).

“a” 2 2

3
3
“A” “B”

IFL311210033-03 IFL311210035-01

“a”: Clearance (Max. 2.5 mm, 0.09 in.)

“A”: Lever
“B”: Stopper 4

8) Operate the throttle control grip and check that the

throttle valve opens and closes completely without
interference.

NOTE
If the throttle valve does not operate 5
smoothly or open/close completely, check for
the throttle cable routing or inner cable
IFL311210036-02
tension.
4) Remove the steering friction adjuster assembly (6).

Steering Friction Adjuster Disassembly and

Assembly
CENFL3122106005
Disassembly
Removal
1) Remove both lower side covers.
Refer to “Lower Side Cover Removal and
6
Installation” (Page 2A-3).
2) Remove the two bolts (1) securing handle bracket.

IDK111210039-01

1
IFL311210034-01
2A-8 Housing and Bracket:

Disassembly Assembly
1) Remove the steering adjuster plate (1). Assemble the steering friction adjuster set in the
following sequence:

Reassembly
1) Thread the shaft (1) to the adjuster base plate (2) as
shown in the figure.

1
IDK111210040-01

2
2
3
IDK111210041-01
4
2) Install the friction washer (3), spacer (4) and friction
washer (5).
5

6
5

8
4

3
IDK111210042-01
1
3) Install the upper plate (6) and washer (7).

9
10

7
11

6
12
IDK111210043-01
IDK111210003-02

2) Remove the friction adjuster nut (2), washer (3),

washer (4) and adjuster lever (5).
3) Remove the washer (6) and upper plate (7).
4) Remove the friction washer (8) and spacer (9).
5) Remove the friction washer (10).
Loosen and remove the shaft (11) from adjuster
base plate (12).
 Housing and Bracket: 2A-9

4) Install the steering adjuster lever (8), washer (9) and Installation
washer (10). 1) Place the steering friction adjuster assembly into
position.
NOTE
2) Apply Thread Lock 1342 to the threads of adjuster
When install the washer (9) and (10), put
mounting bolts before threading them.
rough face of each washer together.
3) Temporarily tighten all mounting bolts.
4) Tighten the bolts (1) to specified torque.
10 Tightening torque
Bolt (a): 10 N·m (1.0 kgf-m, 7.2 lbf-ft)
5) Move the steering adjuster lever to fully left position.
Tighten the bolt (2), and then tighten bolt (3) to
9 specified torque.
Tightening torque
8 Bolt (b): 10 N·m (1.0 kgf-m, 7.2 lbf-ft)

IDK111210044-01

5) Place the steering adjuster plate (11) between the

friction washer (3) and (5).

11
1 (a)
IFL311210037-01

IDK111210045-02

6) Install the friction adjuster nut (12).

Move the steering adjuster lever to fully left position.
Tighten the friction adjuster nut (12) to specified
torque.
3 (b)
2 (b)
Tightening torque
Steering friction adjuster nut (a): 9 N·m (0.9 kgf-
m, 6.5 lbf-ft) IFL311210038-01

6) Install the handle bracket.

Refer to “Tiller Handle and Handle Bracket Removal
and Installation” (Page 2A-4).

12 (a)

IDK111210046-01
2A-10 Housing and Bracket:

Tiller Handle Components

CENFL3122106006

14

13

17 18
16 (b)
19

15

8
9
10
11
12
2

3
4

6
7 (a)
IFL312210001-01

1. Tiller handle 9. Nut 17. Lock plate

2. Throttle rod 10. Support 18. Cap
3. Bushing 11. Screw 19. Plate
4. Spring 12. Knob : 3 N⋅m (0.3 kgf-m, 2.1 lbf-ft)
5. Handle grip 13. Throttle cable : 1.8 N⋅m (0.18 kgf-m, 1.3 lbf-ft)
6. Lock washer 14. Throttle cable : Apply SUZUKI water resistant grease.
7. Screw 15. Emergency / Stop switch : Apply SUZUKI thread lock 1342.
8. Plate 16. Nut
 Housing and Bracket: 2A-11

Tiller Handle Disassembly and Assembly 3) Remove the screws (4), throttle adjuster knob (5)
CENFL3122106007 and lower plate (6).
Disassembly
1) On the PTT model;
Remove the bolts and PTT switch (1).

4
5

IFL312210054-01

1 4) Remove the spring (7) and bush (8) from throttle rod.

IFL312210052-01

2) Remove the screw (2) and throttle grip (3).

2 IFL312210055-01

3 5) Remove the throttle rod (9) and throttle cable

assembly.
IFL312210053-01
Remove the throttle cables (10) from throttle rod.

10

IFL312210056-01
2A-12 Housing and Bracket:

Assembly 4) Install the lower plate (5), throttle adjuster knob (6),
Assembly is in the reverse order of disassembly with then securely tighten it with screws.
special attention to the following steps.
Reassemble the tiller handle, refer to “Tiller Handle
Components” (Page 2A-10).
1) Install the throttle cables (1) to throttle rod.

6
IDK111210058-01

5) Install the throttle grip (7), then tighten screw (8),

1 pre-coated with thread lock, to specified torque.
Tightening torque
IDK111210054-01
Throttle grip screw (a): 3 N·m (0.3 kgf-m, 2.1 lbf-
2) Place the throttle rod/cable assembly (2) into ft)
position.
: Thread lock cement 99000–32050
(SUZUKI Thread Lock 1342 (50 g))
2

8 (a)

IFL312210057-01 7
3) Insert the bush (3) to tiller handle and install spring
IDK111210059-01
(4) to throttle rod.

3
4

IDK111210056-01
 Housing and Bracket: 2A-13

Engine Holder / Driveshaft Housing / Mounts Components

CENFL3122106008

3
4

15
6
5
7
5
8 16
12 (a)
14
9

10
11

13 (b)
IFL311210115-01

1. Gasket 6. Upper mount bolt 11. Washer 16. Bolt

2. Engine holder 7. Upper mount 12. Nut : 40 N⋅m (4.0 kgf-m, 29.0 lbf-ft)
3. Dowel pin 8. Mount cover 13. Bolt : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft)
4. Driveshaft upper oil seal 9. Upper mount seal 14. Oil strainer : Apply SUZUKI thread lock 1342.
5. Thrust stopper 10. Upper mount seal No.2 15. O-ring : Apply SUZUKI water resistant grease.
2A-14 Housing and Bracket:

3
4 (a)
5
6 (b)

8
7

11
18

10
16
12
13
9
13
17

14 (c)

15 (c)
IFL311210116-02

1. Gasket 9. Lower thrust mount 17. Water tube guide

2. Driveshaft housing 10. Lower side mount 18. Grommet
3. Dowel pin 11. Lower mount cover STBD : 13 N⋅m (1.3 kgf-m, 9.5 lbf-ft)
4. Oil drain plug 12. Lower mount cover PORT : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft)
5. Gasket 13. Pin : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft)
6. Bolt 14. Bolt : Apply SUZUKI thread lock 1342.
7. Water plug 15. Bolt
8. Gasket 16. Water tube
 Housing and Bracket: 2A-15

Engine Holder / Driveshaft Housing / Mounts 5) Remove the PORT lower mount cover (4) and lower
Disassembly side mount (5).
CENFL3122106009
1) Remove the power unit.
Refer to “Power Unit Removal and Installation” in
Section 1D (Page 1D-15). 5
2) Remove the lower unit.
Refer to “Lower Unit Removal and Installation” in
Section 3A (Page 3A-5).
3) Remove the four bolts (1) securing PORT/ STBD
lower mount covers.

4
IFL311210042-01

6) Remove the lower thrust mount (6) and pilot shaft

washer (7).

7
IFL311210039-01

IFL311210043-01

7) On PORT/STBD both sides;

remove upper mount nuts (8) and washers (9).

1
IFL311210040-01

4) Remove the STBD lower mount cover (2) and lower

side mount (3).
9
8

3 IFL311210044-01

8) Remove engine holder and driveshaft housing

assembly (10).

10

2
IFL311210041-01

IFL311210045-01
2A-16 Housing and Bracket:

9) Remove the upper mount seal (11). 13) Remove the pin (18) and side cover seal (19).

19

18
11

IFL311210046-01 IFL311210050-02

10) Remove the bolts (12) and PORT/STBD upper 14) Remove the two bolts and oil strainer (20).
mount covers (13).

20

12

13

IFL311210051-02

IFL311210047-01 15) Remove the water tube guide (21), water tube (22)
11) Remove the upper mounts (14), mount stoppers (15) and water tube grommet (23).
and upper mount bolts (16).

16
15
14 15
23

16
21
15
14 22
15
IFL311210010-02
IFL311210048-01

12) Remove the eight bolts and the engine holder (17)
from the driveshaft housing.

17

IFL311210049-01
 Housing and Bracket: 2A-17

Engine Holder / Driveshaft Housing / Mounts • Install two dowel pins (6) and gasket (7) to driveshaft
Assembly housing.
CENFL3122106010
Assembly is in reverse order of disassembly with special NOTICE
attention to the following steps. Previously used gasket may leak oil and/or
cooling water, resulting in engine damage.
Engine Holder to Driveshaft Housing
• Apply water resistant grease to water tube grommet Do not reuse gasket. Always assemble with a
(1), then install the water tube grommet to driveshaft new gasket.
housing.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
6 6
• Install the water tube (2) and water tube guide (3).

7
1

IFL311210054-01

• Install engine holder (8) to driveshaft housing (9).

3 Apply engine oil to the driveshaft housing bolts (10)
2 before threading it. Tighten driveshaft housing bolts to
specified torque.
IAJ311210006-02

• Apply engine oil to O-rings (4), then install O-rings to Tightening torque
oil strainer (5). Driveshaft housing bolt (a): 23 N·m (2.3 kgf-m,
16.5 lbf-ft)
• Install oil strainer to engine holder, then tighten bolts
securely.
8
10 (a)

5
4

IFL311210055-01

IFL311210052-02

IFL311210053-02
2A-18 Housing and Bracket:

Upper Mount • Tighten mount cover bolts, pre-coated with thread

• Assemble two mount stoppers (1) and mount bolt (2) lock, to specified torque.
to each upper mount (3). Tightening torque
Upper mount cover bolt (a): 23 N·m (2.3 kgf-m,
16.5 lbf-ft)
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))

1 3
(a)

2
IFL311210056-02

• Install the upper mount assembly into engine holder.

IFL311210059-01

Engine Holder and Driveshaft Housing

• Install the upper mount seal (1).

IFL311210057-01

• Install mount cover (4).

Be sure retaining pin “A” on mount cover properly fits
into the retaining pin hole “B” on the mount.
1

“A”
4
IFL311210060-01

“B”

IFL311210058-01
 Housing and Bracket: 2A-19

• Install engine holder and driveshaft housing to • Install the lower side mount (3).
steering bracket.
• Install washer (2) and upper mount nut (3), then
tighten two nuts, pre-coated with thread lock, to
specified torque.
Tightening torque
Upper mount nut (a): 40 N·m (4.0 kgf-m, 29.0 lbf-
ft)
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g)) 3

IFL311210064-01

• Install pin (4) to PORT lower mount cover (5).

• Place PORT lower mount cover (5) to driveshaft
housing and steering shaft.

NOTE
2
When attaching the lower mount cover to
3 (a) steering shaft, ensure that the retaining pin
(4) properly fits into the hole “A” of steering
shaft.
IFL311210061-02

“A”

2
3 (a)
4

IFL311210062-02 IFL311210065-01

Lower Mount and Lower Mount Cover

• Install the pilot shaft washer (1) and lower thrust
mount (2).

5
1
IFL311210066-01

IFL311210063-01
2A-20 Housing and Bracket:

• Install the lower side mount (6). • Install the lower mount cover bolts, then tighten bolts,
pre-coated with thread lock, to specified torque.
Tightening torque
Lower mount cover bolt (a): 23 N·m (2.3 kgf-m,
16.5 lbf-ft)
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))

IFL311210067-01

• Install the pin (7) to STBD lower mount cover (8).

• Install STBD lower mount cover (8) to driveshaft
housing and steering shaft. (a)

NOTE
When attaching the lower mount cover to
IFL311210070-01
steering shaft, ensure that the retaining pin
(7) properly fits into the hole “B” of steering
shaft.

“B”

8 (a)

IFL311210071-01

IFL311210068-02

IFL311210069-02
 Housing and Bracket: 2A-21

Engine Holder / Driveshaft Housing / Mounts Mount Cover

Related Component Inspection • Inspect the mount cover. Replace the mount cover if
CENFL3122106011
cracked, damaged or other abnormal conditions are
Refer to “Engine Holder / Driveshaft Housing / Mounts
found.
Disassembly” (Page 2A-15) and “Engine Holder /
Driveshaft Housing / Mounts Assembly” (Page 2A-17).

NOTE
If any component is found to be excessively
worn, cracked, defective or damaged in any
way, it must be replaced.

Engine Holder
• Inspect the engine holder. Replace if cracked,
damaged, or other abnormal conditions are noted.
• Check water passage. If clogged or obstructed, clean
IFL311210074-01
water passage.
Mount
• Check upper, lower and thrust mounts.
If excessive wear, corrosion or other damage is found,
replace mount.
• Check mount bolts.
If cracks, corrosion or other damage is found, replace
bolt.

IFL311210072-01

Driveshaft Housing
• Check driveshaft housing.
If cracks, defects or other damage is found, replace it.

IFL311210076-01

IFL311210075-01
2A-22 Housing and Bracket:

Oil Strainer Driveshaft Upper Oil Seal Replacement

CENFL3122106012
• Inspect the oil strainer.
Replace the strainer if cracked, damaged or other 1) Remove the engine holder.
abnormal conditions are found. Refer to “Engine Holder / Driveshaft Housing /
If clogged or obstructed, clean the oil strainer. Mounts Disassembly” (Page 2A-15).
• Check condition of O-ring. 2) Extract oil seal with the special tool.
Replace O-ring if nicked, cut, worn or other abnormal Special tool
condition are found. (A): 09913–50121 (Oil seal remover)

(A)

IFL311210077-01 IFL311210079-01

3) Apply water resistant grease to outer circumference

Water Tube / Water Tube Grommet of oil seal.
• Check water tube. 4) Drive the oil seal into the engine holder.
If a clog or obstruction is found, clean water tube.
If cracks, corrosion or other damage is found, replace NOTE
water tube. Install oil seal with lip (spring side) facing
• Check water tube grommet. downward (oil pan side).
If excessive wear or other damage is found, replace
grommet. : Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))

IFL311210078-01
IFL311210003-03

5) Apply enough water resistant grease on oil seal.

6) Reassemble the engine holder.
Refer to “Engine Holder / Driveshaft Housing /
Mounts Assembly” (Page 2A-17).
 Housing and Bracket: 2A-23

Gas Cylinder Unit Removal and Installation (Q 3) Remove the tilt rod snap ring (2) and push the tilt rod
Model) upper shaft pin (3) out until it is extracted from the
CENFL3122106021 cylinder upper eye.
! WARNING
This unit contains high pressure gas and it
must not be disassembled, punctured,
incinerated or exposed to heat. 3

Removal
1) Remove the lower side cover.
Refer to “Lower Side Cover Removal and 2
Installation” (Page 2A-3).
2) Raise the engine to the full tilt up position and lower
the manual tilt lock levers (1). IFL312210026-01

4) Remove the bolt (4) securing gas cylinder lower

shaft to STBD/PORT clamp brackets.

IFL312210025-01

! WARNING
IFL312210058-01
Failure to take proper precaution when
servicing a gas cylinder unit can cause
severe personal injury.

During the removal or installation of gas

cylinder unit, the engine must be firmly
secured and its weight fully supported by the
hoist. (See below)

IFL312210059-01

IFL312210040-01
2A-24 Housing and Bracket:

5) Push out the gas cylinder lower shaft (5). Installation

Installation is reverse order of removal with special
NOTE attention to the following steps.
Screw a 10 mm bolt into the lower shaft and • Apply water resistant grease to the gas cylinder lower
gently tap the bolt using a soft head hammer shaft (2) and lower shaft bushing (1).
to slide the lower shaft out. Install the lower shaft bushing (1) to gas cylinder (3).
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))

3
1

IFL312210060-01

6) Remove the tilt aid gas cylinder unit (6) from 2

between the clamp brackets. IFL312210031-01

• Apply water resistant grease to gas cylinder upper

bushings (4), then install bushings in cylinder upper
eyelet.
6
4

IFL312210029-01

7) Remove the tilt rod snap ring (7) and tilt rod upper
shaft pin (8).
IFL312210032-01

• Place the gas cylinder unit (3), collar (5) and collar (6)
in position between clamp brackets.
Install the gas cylinder lower shaft (2).

8 3
7

IFL312210030-01 5 6

2
IFL312210033-02
 Housing and Bracket: 2A-25

• Tighten cylinder lower shaft bolts (7), pre-coated with Gas Cylinder Related Items Inspection (Q
thread lock, to specified torque. Model)
CENFL3122106022
: Thread lock cement 99000–32050 (SUZUKI Gas Cylinder
Thread Lock 1342 (50 g)) Check the gas cylinder.
Tightening torque If cracks, defects or other damage is found, replace the
Cylinder lower shaft bolt (a): 50 N·m (5.0 kgf-m, gas cylinder assembly complete.
36.0 lbf-ft)

7 (a) 7 (a)
IFL312210037-01

IFL312210034-03
Bushings
• Align the cylinder upper eyelet with the hole in the Check all bushings.
swivel bracket, then insert the upper shaft (8) through If excessive wear or other damage is found, replace
the swivel bracket and gas cylinder. bushing.
Secure the upper shaft with the snap ring (9). If bushing fit is loose when installing, replace bushing.
• Make sure that the snap rings (9) are appropriately
installed in both ends of the upper shaft pin (8).

IFL312210038-01

IFL312210035-02 Upper Shaft / Lower Shaft

Inspect lower shaft and upper shaft for bends, twists or
other damage. Replace if necessary.

IFL312210036-02

IFL312210039-01
2A-26 Housing and Bracket:

Clamp / Swivel / Steering Brackets Components (A/AR models)

CENFL3122106013

10

11
3 12

1 4
5 (a)

2
13 14

17
18
8
7
15
16
9

6
IFL311210117-02

1. Clamp bracket STBD 8. Clamp screw 15. Washer

2. Clamp bracket PORT 9. Clamp plate 16. Nut
3. Clamp bracket shaft 10. Tilt pin 17. Anode
4. Lock washer 11. Spring 18. Bolt
5. Nut 12. Stopper : 43 N⋅m (4.3 kgf-m, 31.0 lbf-ft)
6. Clamp handle 13. Bolt : Apply SUZUKI water resistant grease.
7. Pin 14. Spacer
 Housing and Bracket: 2A-27

41 (a)
40
39
38
37
34
32 2
36

35
34
32 33
31 3

7 4
18
20 (c) 42

21 (b) 8
10
11 22
1
43
17
19
12 15
13 16
14 17 7
8
27
4
25 23
30
5
24
26 9
6
28

29
IFL312210067-01

1. Swivel bracket 17. Circlip 33. Shaft

2. Steering bracket 18. Release lever link 34. Washer
3. Washer 19. Release arm 35. Spacer
4. Bush 20. Lock nut 36. Steering adjuster plate
5. Seal 21. Bolt 37. Upper plate
6. Washer 22. Spring 38. Washer
7. Bush 23. Spring 39. Adjuster lever
8. Grease nipple 24. Release lock arm 40. Washer
9. Shallow drive arm 25. Release lock arm link STBD 41. Nut
10. Rubber 26. Release lock arm link PORT 42. Bonding wire
11. Release lever 27. Pin 43. Screw
12. Bushing 28. Washer : 9 N⋅m (0.9 kgf-m, 6.5 lbf-ft)
13. Spacer 29. Cotter pin : 1 N⋅m (0.1 kgf-m, 0.7 lbf-ft)
14. Bushing 30. Pin : 4 N⋅m (0.4 kgf-m, 3.0 lbf-ft)
15. Pin 31. Friction plate : Apply SUZUKI water resistant grease.
16. Bushing 32. Bolt
2A-28 Housing and Bracket:

Clamp / Swivel / Steering Brackets Disassembly 5) Remove the screw and bonding wire (8) from swivel
(A/AR models) bracket.
CENFL3122106014
1) Remove engine holder / driveshaft housing.
Refer to “Engine Holder / Driveshaft Housing / 8
Mounts Disassembly” (Page 2A-15).
2) Remove the bolts (1) and steering adjuster assembly
(2).

1 2

IFL311210083-01

6) Using flat blade screw driver, drive locking edge of

lock washer (9) to clamp bracket side.

IFL311210080-01

3) Lift steering bracket (3) upward to remove from 9

swivel bracket.
Remove the washer (4), upper bush (5) from swivel
bracket.

3
IFL311210084-01

7) Remove the nut (10) from clamp bracket shaft.

4
5
10

IFL311210081-01

4) Remove the swivel bracket seal (6) and lower bush

(7).

IFL311210085-01
7

6
IFL311210082-01
 Housing and Bracket: 2A-29

8) Remove the tilt lock pin (11). 11) Remove the spring (20) from shallow drive arm.
Remove the nut (12), bolt (13) and spacer (14).

20

11
14 14
11 13
12 IFL311210087-01

IFL311210004-02 12) Loosen the lock nut (21), then remove bolt (22).
9) Remove the PORT clamp bracket (15).

22

21
15

IFL311210088-01

IFL311210086-01 13) Remove the release lever (23) and bushing (24).
10) Pull STBD clamp bracket (16) outward to remove
clamp bracket and bracket shaft (17) from swivel
bracket (18). Remove bushings (19) from each side 24
of swivel bracket.
23
19
18
19
17

IFL311210089-01

14) Remove the circlip (25).

16 Remove the bushing (26) and spacer (27).

IFL311210005-03

27 26
25

IFL311210090-01
2A-30 Housing and Bracket:

15) Remove the release arm (28) and release link (29). 17) Remove two springs (34) from reverse lock arm (35)
and swivel bracket.

28

34

29

35
IFL311210091-01

16) Remove the circlip (30). IFL311210094-01

Push out rod (31), then remove bushing (32). 18) Remove the cotter pin (36), washer (37) and pin
Remove the shallow drive arm (33). (38).
Remove the cotter pin (39) and pin (40).
Remove the reverse lock arm links (41) and reverse
lock arm (42).

38

30 31 32
31
36
42

41
IFL311210092-02
40 37
41
39
IFL311210095-02

33

IFL311210093-01
 Housing and Bracket: 2A-31

Clamp / Swivel / Steering Brackets Assembly 3) Install the bushing (7) and spacer (8).
(A/AR models) Install the circlip (9).
CENFL3122106015
Assembly is reverse order of disassembly with special
attention to the following steps.

Shallow Drive Arm

1) Place the shallow drive arm (1) into position, then
insert the bush (2) and rod (3).
Install the circlip (4).
8 7 9

IFL311210099-02

4) Install the bushing (10) and release lever (11).

10

11
1

IFL311210096-01

IFL311210100-02

5) Tighten the bolt (12) to 1 N⋅m (0.1 kgf-m), and next,

tighten the nut (13) to 4 N⋅m (0.4 kgf-m).
3 2 DO NOT OVER TIGHTEN.
4

12
IFL311210097-01

2) Install the release link (6) to release arm (5) and pin
as shown in figure.
13

6
5

IFL311210101-04

6) Install the spring (14) as shown.

IFL311210098-02

14

IFL311210102-02
2A-32 Housing and Bracket:

Clamp Bracket and Swivel Bracket 4) Install the lock washer (7), clamp bracket shaft nut
(8), then tighten the clamp bracket shaft nut to
NOTE specified torque.
Before installing clamp bracket to swivel
Tightening torque
bracket, apply grease to clamp bracket shaft
Clamp bracket shaft nut (a): 43 N·m (4.3 kgf-m,
and bushings.
31.0 lbf-ft)
: Grease 99000–25350 (SUZUKI Water Resistant
Grease EP2 (250 g)) 8 (a)

1) Insert PORT and STBD bushings (1) into the swivel 7

bracket (2).

2
1
1

IFL311210105-01

5) After tightening clamp bracket shaft nut to specified

torque, bend lock washer edge toward nut to secure
nut.

IFL311210006-03

2) Assemble the clamp bracket shaft (3), STBD clamp

bracket (4) and swivel bracket (5).

4
5
3

IFL311210106-01

Steering Bracket

IFL311210103-01
NOTE
3) Install PORT clamp bracket (6). Apply grease to bushings, seal and pilot
shaft portion of steering bracket.

: Grease 99000–25350 (SUZUKI Water Resistant

Grease EP2 (250 g))

IFL311210104-01
 Housing and Bracket: 2A-33

1) Install the upper bushing (1), washer (2) and steering Bonding Wire
bracket to swivel bracket. Reattach bonding wire (1) to swivel bracket and tighten
screw securely.
NOTE
The bushing (1), (3) outside face is tapered.
Install the bushing into the swivel bracket
with the smaller diameter side being inserted
first. 1

2
IFL311210108-01
1

Lubrication
After completing reassembly of the mid unit, apply
grease through each grease nipple.
: Grease 99000–25350 (SUZUKI Water Resistant
IFL311210007-02
Grease EP2 (250 g))
2) Install the lower bushing (3) and swivel bracket seal
(4) to swivel bracket.

NOTE
Install bracket seal (4) with oil seal lip (spring
side) facing downward

3
IFL311210109-01

IFL311210008-02

Steering Friction Adjuster

1) Install the steering friction adjuster (1).
Refer to “Steering Friction Adjuster Disassembly and
Assembly” (Page 2A-7).
IFL311210110-01

IFL311210107-01
2A-34 Housing and Bracket:

Clamp / Swivel / Steering Brackets Related Clamp Bracket Shaft

Components Inspection (A/AR models) Check clamp bracket shaft.
CENFL3122106016 If clamp bracket shaft is bent or twisted, replace shaft.
Refer to “Clamp / Swivel / Steering Brackets
Disassembly (A/AR models)” (Page 2A-28) and “Clamp /
Swivel / Steering Brackets Assembly (A/AR models)”
(Page 2A-31).

NOTE
If any component is found to be excessively
worn, cracked, defective or damaged in any
way, it must be replaced.

Bushings
Check all bushings. If excessive wear or other damage
is found, replace bushing. If bushing fit is loose when IFL311210111-01

installing, replace bushing.

Bracket
Check clamp brackets, steering bracket and swivel
bracket.
If cracks or other damage is found, replace bracket (s).

IFL311210009-02

Oil Seal
Check swivel bracket seal. If excessive wear or other
damage is found, replace seal. IFL311210112-01

IAJ311210134-01
 Housing and Bracket: 2A-35

Clamp / Swivel / Steering Brackets Components (T/Q Model)

CENFL3122106017

5 (a) 1

3
10
11

13
12
15
14

7 8

16
17
IFL312210065-01

1. Clamp bracket STBD 8. Clamp screw 15. Nut

2. Clamp bracket PORT 9. Clamp plate 16. Anode
3. Clamp bracket shaft 10. Washer 17. Bolt
4. Lock washer 11. Bolt : 43 N⋅m (4.3 kgf-m, 31.0 lbf-ft)
5. Nut 12. Tilt pin : Apply SUZUKI water resistant grease.
6. Clamp handle 13. Washer
7. Pin 14. Washer
2A-36 Housing and Bracket:

37 (a)
36
35
34
33
6
30

32

31
30 2
8
7
28 9
29

27

10 3

11
4
1
16
17 18

21
23
12

13 24
25 26 19
20
22

12

15 4
14
5

3
IFL312210066-02

1. Swivel bracket 14. Anode 27. Friction plate

2. Steering bracket 15. Bolt 28. Bolt
3. Washer 16. Bushing 29. Shaft
4. Bushing 17. Tilt lock lever link 30. Washer
5. Seal 18. Washer 31. Spacer
6. Steering bracket attachment 19. Spring 32. Steering adjuster plate
7. Washer 20. Tilt lock lever PORT 33. Upper plate
8. Stud bolt 21. Washer 34. Washer
9. Nut 22. Nut 35. Steering adjuster lever
10. Tilt lock lever STBD 23. Pin 36. Washer
11. Bushing 24. Tilt lock spring bracket 37. Nut
12. Bushing 25. Screw : 9 N⋅m (0.9 kgf-m, 6.5 lbf-ft)
13. Grease nipple 26. Spring : Apply SUZUKI water resistant grease.
 Housing and Bracket: 2A-37

Clamp / Swivel / Steering Brackets Disassembly 5) Remove circlip (6) and push out tilt cylinder upper
(T/Q Model) rod (7) until it is extracted from tilt rod upper eye (or
CENFL3122106018 gas cylinder upper eye).
1) Remove engine holder and driveshaft housing.
Refer to “Engine Holder / Driveshaft Housing /
Mounts Disassembly” (Page 2A-15).
2) Remove the bolts and steering adjuster assembly. 6

IFL312210005-01

6) Remove the bolt (8) securing PTT lower shaft to

clamp brackets.

IFL312210002-01

3) Lift steering bracket (1) upward to remove from

swivel bracket.
Remove washer (2) and upper bushing (3).

8
1

IFL312210061-01
2

IFL312210003-01

4) Remove swivel bracket seal (4) and lower bushing

(5).

IFL312210062-01

IFL312210004-01
2A-38 Housing and Bracket:

7) Using flat blade screw driver, drive locking edge of 11) On the Q model;
lock washer (9) to clamp bracket side. Remove the gas cylinder unit (15).
8) Remove the two STBD motor mounting bolts (10). Refer to “Gas Cylinder Unit Removal and Installation
Loosen the STBD clamp screw (11). (Q Model)” (Page 2A-23).
Remove the clamp bracket shaft nut (12) and
washer.
13

12

9 15
11

10 IFL312210009-01

12) Pull PORT clamp bracket (16) outward to remove

IFL312210007-01 clamp bracket and bracket shaft (17) from swivel
9) Slide STBD clamp bracket (13) off clamp bracket bracket (18). Remove bushing (19) from each side of
shaft. swivel bracket.
10) On the PTT model;
Remove the PTT unit (14). 18
Refer to “Power Trim and Tilt Unit Removal and
Installation” in Section 2B (Page 2B-11).
19
13 19
16

14

17
IFL312210010-02

IFL312210008-01
 Housing and Bracket: 2A-39

Clamp / Swivel / Steering Brackets Assembly (T/ • Install PTT unit and lower shaft assembly (5).
Q Model) Refer to “Power Trim and Tilt Unit Removal and
CENFL3122106019 Installation” in Section 2B (Page 2B-11).
Assembly is reverse order of disassembly with special
attention to the following steps.

Clamp Bracket / Swivel Bracket

NOTE
5
Before installing clamp bracket to swivel
bracket, apply grease to clamp bracket shaft
and bushings.

: Grease 99000–25350 (SUZUKI Water Resistant

Grease EP2 (250 g))
IFL312210013-01
• Insert PORT and STBD bushings (2) into the swivel
• Install the gas cylinder unit (6).
bracket (1).
Refer to “Gas Cylinder Unit Removal and Installation
(Q Model)” (Page 2A-23).

2 2

IFL312210063-01

• Assemble PORT clamp bracket (3), clamp bracket IFL312210014-01

shaft (4) and swivel bracket (1).
• Install STBD clamp bracket (7), lock washer (8) and
clamp bracket shaft nut (9).

9
8

3
1
IFL312210064-01 7

IFL312210015-01
2A-40 Housing and Bracket:

• Tighten clamp bracket shaft nut (9) to specified Steering Bracket

torque. • Apply water resistant grease to steering bracket shaft.
• After tightening clamp bracket shaft nut to specified
: Grease 99000–25350 (SUZUKI Water
torque, bend lock washer edge toward nut to secure
Resistant Grease EP2 (250 g))
nut.
Tightening torque NOTE
Clamp bracket shaft nut (a): 43 N·m (4.3 kgf-m, Apply grease to bushings, oil seal lip and
31.0 lbf-ft) pilot shaft portion of steering bracket.

NOTE
(a)
The bushing (1), (3) outside face is tapered.
Install the bushing into the swivel bracket
with the smaller diameter side being inserted
first.

• Install upper bushing (1) and washer (2) to swivel

bracket.
• Install lower bushing (3) and swivel bracket seal (4) to
swivel bracket.
IFL312210016-01

• Tighten two PTT lower shaft bolts, pre-coated with NOTE

thread lock, to specified torque. Install bracket seal (4) with oil seal lip (spring
side) facing downward.
Tightening torque
PTT lower shaft bolt (b): 50 N·m (5.0 kgf-m, 36.0 • Install steering bracket (5) to swivel bracket.
lbf-ft)
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))

5
2

1
IFL312210018-01
(b) (b)

IFL312210017-01

5 3

IFL312210019-01
 Housing and Bracket: 2A-41

Lubrication Bushings
After completing reassembly of the mid unit, apply Check all bushings. If excessive wear or other damage
grease through each grease nipple. is found, replace bushing. If bushing fit is loose when
installing, replace bushing.
: Grease 99000–25350 (SUZUKI Water Resistant
Grease EP2 (250 g))

IFL312210022-01

IFL312210020-01
Oil Seal
Check swivel bracket seal. If excessive wear or other
damage is found, replace seal.

IFL312210021-01

Clamp / Swivel / Steering Brackets Related I9J011210118-01

Components Inspection (T/Q Model)
CENFL3122106020 Clamp Bracket Shaft
Refer to “Clamp / Swivel / Steering Brackets Check clamp bracket shaft.
Disassembly (T/Q Model)” (Page 2A-37) and “Clamp / If clamp bracket shaft is bent or twisted, replace shaft.
Swivel / Steering Brackets Assembly (T/Q Model)” (Page
2A-39).

NOTE
If any component is found to be excessively
worn, cracked, defective or damaged in any
way, it must be replaced.

IFL312210023-01
2A-42 Housing and Bracket:

Bracket
Check clamp brackets, steering bracket and swivel
bracket.
If cracks or other damage is found, replace bracket (s).

IFL312210024-01
 Power Trim and Tilt: 2B-1

Power Trim and Tilt

Mid Unit

Precautions
Precaution for Power Trim and Tilt
CENFL3122200001
! WARNING
Failure to take proper precaution when servicing a PTT unit can cause severe personal injury.

Be sure to take the following precautions when servicing the PTT system:
• During removal or installation of PTT unit, the engine must be firmly secured and its weight fully
supported by the hoist.
• Before checking PTT fluid level, tilt the motor to the full-up position and engage the tilt lock lever.

NOTE
• To prevent system malfunctions, ensure that all components are kept free from dirt or
contamination.
• Reinstall all O-rings, seals, springs etc. with the component(s) to which they belong. This will
prevent possible confusion and will ensure correct reassembly.
2B-2 Power Trim and Tilt:

General Description
Power Trim and Tilt Description
CENFL3122201001
The power trim and tilt system components are an electric motor, a pump unit, a fluid reservoir and one tilt cylinder.
The outboard can be trimmed “UP” or “DOWN” while under way, and can be tilted for beaching, operating in shallow
water or trailering.
Trim and tilt “UP” or “DOWN” is obtained by supplying power to a permanent magnet type motor. This motor will rotate
clockwise for “UP” or counterclockwise for “DOWN”, according to power delivered via the PTT relay, which is mounted
on the electric part holder.

Power Trim and Tilt Hydraulic Diagram

14

13

15
1

2
16

3
17

18
7 6
8

9 11 10

12
IFL312220055-02

1. Oil reservoir 7. “Down” relief valve 13. PTT cylinder

2. Oil filler cap 8. Spool valve 14. Tilt rod
3. PTT motor 9. “Down” pressure main check valve 15. Upper cylinder chamber
4. Check valve “A” 10. “Up” pressure main check valve 16. Piston
5. Check valve “B” 11. “Up” relief valve 17. Free piston
6. Gear pump 12. Manual release valve 18. Lower cylinder chamber
 Power Trim and Tilt: 2B-3

Principles of Power Trim and Tilt Operation Description

CENFL3122201002
By motor operation, the geared pump will be driven, and by turning the motor to the right or to the left, oil flow will
change its direction. This causes “UP” and “DOWN” movements of the piston rod of the tilt cylinder.

Trim / Tilt Up Circuit

The electric motor (1) is operating in a clockwise direction. Check valve (2) will open, allowing oil to flow from the
reservoir (3) to the pump (4). Oil flow from the pump enters the spool valve (5), moving it to the left, opening the
“down” pressure main check valve (6) and returning oil from the upper cylinder chamber (7) (plus oil from the
reservoir) to the pump. Pressure built up by the pump will then open the “up” pressure main check valve (8) and oil will
enter the lower cylinder chamber (9).
When PTT motor stops, both the “DOWN” pressure main check valve (6) and the “up” pressure main check valve (8)
will close to retain tilt/trim position.
When full trim/tilt “up” position is attained, sustained operation of the “up” relay will have no effect, as pump oil flow will
be returned to the reservoir through the “up” relief valve (10).

7
3

2
4

6
5 10 8

IFL312220056-01
2B-4 Power Trim and Tilt:

Tilt / Trim Down Circuit

The electric motor (1) is operating in a counterclockwise direction. Check valve (2) will open, allowing oil to flow from
the reservoir (3) to the pump (4). Oil flow from the pump enters the spool valve (5), moving it to the right, thereby
opening the “up” pressure main check valve (6). Oil from the lower cylinder chamber (7) will go through the “up”
pressure main check valve (6) to the pump.
Pressure built up by the pump will open the “down” pressure main check valve (8) and oil will enter the upper cylinder
chamber (9). The piston (10) will retract (move inward), which will tilt the outboard down. Oil in the lower cylinder
chamber (7) is returned to the pump through the “up” pressure main check valve (6).
When full “down” position is reached, continued operation of the “down” relay will have no effect, as pump oil flow will
be returned to the reservoir through the “down” relief valve (11).

10

7
11
2
4

8
5 6

IFL312220057-01
 Power Trim and Tilt: 2B-5

Shock Absorber Circuit

Shock valve
Should the lower unit strike an underwater object while in motion, the piston will rise abruptly, creating a sudden high
impact pressure in the upper cylinder chamber (1). The shock valve (2) will then open, allowing oil to flow into the area
between the tilt ram piston (3) and the free piston (4), thereby dampening (absorbing) the impact.
Return valve
When the point of impact has passed, propeller thrust and motor weight will force the tilt ram piston back downward.
The oil from between the ram piston (3) and the free piston (4) is then expelled through the return valve (5) before
flowing into the upper cylinder chamber (1).

2 5

IFL312220058-01
2B-6 Power Trim and Tilt:

Manual Release Circuit (Manual Valve)

Turn the manual valve (1) a maximum of three full turns counterclockwise.
When the manual release valve (1) is loosened, oil will flow unimpeded (without resistance) through the internal pump
tubes, thereby facilitating manual tilting or lowering of the outboard. To hold the engine in a selected position, the
manual valve (1) must be closed again.

1
IFL312220059-01
 Power Trim and Tilt: 2B-7

Thermal Valve
The PTT system incorporates a thermal valve (1) for protection of the internal components, should excessive
downward force be exerted on the lower unit with the motor in a tilted position, or (in the case of an impact in reverse
gear), the outboard clamp/swivel brackets and the boat transom.
Should the propeller strike an underwater object whilst in reverse gear, a build up of pressure will be induced in the
lower cylinder chamber (2), whereby the outboard mounting bracket and/or the boat transom may sustain damage. To
prevent this, the thermal valve will open to relieve the oil pressure, thereby softening the impact.
Internal PTT circuits are protected, as the thermal valve will open to reduce oil pressure (caused by either hot climate
or abnormally heavy usage).

1
IFL312220060-01
2B-8 Power Trim and Tilt:

Schematic and Routing Diagram

Power Trim and Tilt System Diagram
CENFL3122202001
DF25ATH/30ATH

3
“A” W/R R R R M

R
R B
2
W/R

B
1
W/R
Lbl
P

B
R
Lbl
P
B
B/W

4
5

IFL312220001-01

1. Battery 3. Fuse (30 A) 5. PTT motor

2. PTT switch 4. PTT relay “A”: To starter switch

DF25AT/30AT

5
R R R R M
R

R B
4
W/R

B
1
W/R
Lbl
P

3 B
R
DN UP
Lbl
P
B
B/W
PUSH FREE ST IG OFF

2 GND B
STOP G
Lbl
W/R
Lbl
W/R
6
BATT W P P
SUZUKI

IG Gr Lbl
P
Lbl
P
7
START Br
B.Z
O W R
RESET W W
PUSH TURN
W/R W/R

IFL312220002-02

1. Battery 5. Fuse (30 A)

2. Ignition switch 6. PTT relay
3. PTT switch (Remote control box) 7. PTT motor
4. PTT switch (Lower side cover)
 Power Trim and Tilt: 2B-9

Diagnostic Information and Procedures

Diagnose PTT System Malfunction
CENFL3122204001

Condition Possible cause Correction / Reference Item

Motor will not trim / tilt at Blown fuse for PTT system. Inspection and replace.
all (no up, no down). Defective PTT switch. Replace.
Defective PTT relay. Replace.
Defective PTT system circuit. Inspection of system circuit.
Loose or corroded battery cable Repair or retighten.
connection.
Open circuit between main fuse and Repair.
starter motor relay.
Defective PTT motor armature. Replace.
Defective PTT motor armature brushes. Replace.
Defective PTT pump. Replace.
Manual release valve leaking. • Ensure that valve is fully closed.
• Inspect manual release valve.
Motor will not trim / tilt up. Defective PTT switch. Replace.
Defective PTT relay. Replace.
Open light blue lead wire circuit. Repair or replace.
Motor will not trim / tilt Defective PTT switch. Replace.
down. Defective PTT relay. Replace.
Open pink lead wire circuit. Repair or replace.
PTT motor operates, but Low PTT fluid level. Added PTT fluid.
no motor trim / tilt Manual release valve leaking. • Ensure that valve is fully closed.
movement. • Inspect manual release valve.
Debris in system. Inspect for debris.
Broken drive joint in PTT pump. Replace.
Broken PTT pump. Replace.
Tilt piston leaking. Replace PTT unit assembly.
Motor will not retain Manual release valve leaking. • Ensure that valve is fully closed.
selected trim and tilt • Inspect manual release valve.
setting, creeps Tilt piston leaking. Replace PTT unit assembly.
downward. Debris in system. Inspect for debris.
PTT motor operates at Low PTT fluid level. Added PTT fluid.
higher than normal speed, Manual release valve leaking. • Ensure that valve is fully closed.
or with high pitched • Inspect manual release valve.
“squealing” sound. No Broken drive joint in PTT pump. Replace.
trim / tilt action.
2B-10 Power Trim and Tilt:

Service Instructions
Checking PTT Fluid Level Air Bleeding from PTT Unit
CENFL3122206001 CENFL3122206002
1) Raise the engine to a full-tilt up position. 1) Check that the manual release valve (1) is tightened
2) Lower the manual tilt lock lever (1). to the specified torque.

NOTE
Do not over tighten manual release valve.
1
Tightening torque
Manual release valve (a): 1.7 N·m (0.17 kgf-m,
1.2 lbf-ft)
Direction of rotation
Counterclockwise: Open
Clockwise: Close

IFL312220003-01

3) Remove the oil filler plug (2).

1 (a)

2 IFL312220005-01

2) Operate the PTT switch, raising and lowering the

motor up and down (full tilt position to full trim down
IFL312220004-01
position) 4 to 5 times.
4) If oil can be seen at filler plug level, the reservoir is
full.
If fluid level is low, refill with the recommended PTT
fluid.

NOTICE
Mixing of different fluids may cause chemical
reaction and deterioration.

To ensure consistent pump operation, never

mix different types of PTT fluid.
IFL312220062-01
Recommended PTT fluid 3) Check PTT fluid level, topping off if necessary.
• 99000-22810 (PTT Fluid (1 Liter)) 4) Reinstall oil filler plug.
• Dexron III automatic transmission fluid or
equivalent

Fluid level
(When full tilted)

IFL312220061-02

5) Reinstall oil filler plug (2).

 Power Trim and Tilt: 2B-11

Power Trim and Tilt Unit Removal and 3) Remove the tilt rod snap ring (2) and push the tilt rod
Installation upper shaft pin (3) out until it is extracted from the tilt
CENFL3122206005 rod upper eye.
Removal
1) Remove the lower side covers.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
3
2) Raise the engine to the full tilt up position and lower
the manual tilt lock lever (1).

IFL312220008-01

4) Lower the tilt rod to the full down position and

disconnect the battery cable.

IFL312220006-01

! WARNING
Failure to take proper precaution when
servicing a PTT unit can cause severe
personal injury.

During the removal or installation of PTT unit,

the engine must be firmly secured and its IFL312220009-01
weight fully supported by the hoist. (See 5) Disconnect the PTT motor cable lead wire connector
below) (4) from PTT relay.
Remove the PTT motor cable (5) from engine lower
cover.

5
IFL312220007-03

IFL312220010-01
2B-12 Power Trim and Tilt:

6) Remove the PTT cylinder lower shaft bolt (6). 9) Remove the tilt rod snap ring (9) and tilt rod upper
shaft pin (10).

6
10

IFL312220063-01
IFL312220014-01

Installation
Installation is reverse order of removal with special
attention to the following steps.
• Lower tilt rod to full down position.
6
• Apply water resistant grease to the tilt cylinder lower
shaft (1) and lower shaft bushings (2).
Install the bushings (2) to PTT unit (3).
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
IFL312220064-01

7) Push out the PTT cylinder lower shaft (7).

NOTE 3
Screw a 10 mm bolt into the lower shaft and
gently tap the bolt using a soft head hammer
to slide the lower shaft out. 2 2

IFL312220015-01

• Place the PTT unit (3) and collars (4) in position

between clamp brackets.

7
3
IFL312220012-02

8) Remove the PTT unit (8) from between the clamp

brackets.
4
4

IFL312220016-01
8

IFL312220013-01
 Power Trim and Tilt: 2B-13

• Install the tilt cylinder lower shaft (1). • Apply water resistant grease to the tilt rod upper shaft
pin (7), then insert the shaft pin through the swivel
bracket and tilt rod.
Secure the upper shaft with the snap rings (8).
Make sure that the snap rings are appropriately
installed in both ends of the shaft pin.
: Grease 99000–25350 (SUZUKI Water
1 Resistant Grease EP2 (250 g))

IFL312220017-01
7
• Tighten two lower shaft bolts (5), pre-coated with
thread lock, to specified torque.
: Thread lock cement 99000–32050 (SUZUKI 8
Thread Lock 1342 (50 g))
Tightening torque
PTT cylinder lower shaft bolt (a): 50 N·m (5.0 kgf- IFL312220020-01
m, 36.0 lbf-ft)

7
8

5 (a) 5 (a)

IFL312220021-01
IFL312220018-01
• Route the PTT motor cable properly through the lower
• Apply water resistant grease to tilt rod upper bushings
cover and connect the PTT cable connector to PTT
(6), then install bushings in tilt rod.
relay.
Operate the PTT motor to extend the PTT rod upward.
Refer to “Wiring Harness Routing Diagram” in Section
Align the tilt rod with the hole in the swivel bracket as
4A (Page 4A-7).
the tilt rod extends.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))

IFL312220022-01

IFL312220019-02
2B-14 Power Trim and Tilt:

Power Trim and Tilt Unit Components

CENFL3122206006

(c)
1

2
6

3
4
7

10
(a)

11

12 22

13
14
15
16
17
18

19

20 (b)
21
IFL312220066-02

1. Reservoir 10. O-ring 19. Circlip

2. Plug 11. Drive joint 20. Manual valve
3. Clamp 12. Pump assembly 21. Seal washer
4. O-ring 13. O-ring 22. Manifold assembly
5. Field case 14. Spring : 5 N⋅m (0.5 kgf-m, 3.6 lbf-ft)
6. Screw 15. Pressure valve : 1.7 N⋅m (0.17 kgf-m, 1.2 lbf-ft)
7. Armature 16. Ball : 4.5 N⋅m (0.45 kgf-m, 3.3 lbf-ft)
8. O-ring 17. Valve sheet
9. Brush holder 18. O-ring
 Power Trim and Tilt: 2B-15

Power Trim and Tilt Unit Disassembly and 4) Connect the PTT cable extension leads (R, B) to
Reassembly battery and operate PTT motor until tilt rod is at
CENFL3122206007 maximum stroke (full-tilt up position). Unscrew the
Disassembly filler plug (1) and drain PTT oil into a suitable
1) Remove Power Trim and Tilt unit. container.
Refer to “Power Trim and Tilt Unit Removal and
Installation” (Page 2B-11).

NOTE
Before disassembly, wash the PTT body with
a stiff bristle brush and hot, soapy water to
remove sand or dirt. Dry the PTT body with
compressed air. (A)

2) Place the lower section of the PTT unit in a vise.

Tighten the vise only enough to secure the PTT unit,
DO NOT OVER TIGHTEN.

NOTE
IFL312220024-01
To prevent damage to the PTT cylinder use
wood blocks, vise jaw protectors, etc.,
between the vise jaws and PTT components
before tightening vise.

IFL312220025-02

5) Remove two screws (2), then detach the reservoir

(3).

IFL312220023-02

3) Connect the PTT cable extension to PTT motor

3
cable connector.
Special tool
(A): 09945–79410 (PTT cable extension)

2
IFL312220026-02

NOTE
Do not lay PTT components out on a rag, as
dirt or lint may be transferred to these items
which may cause possible system operating
problems.
Arrange all components on a clean sheet of
paper.
2B-16 Power Trim and Tilt:

6) Detach the PTT motor (4) from the pump and 8) Remove the three screws (10) and pump assembly
manifold assembly. (11).
Note the position of drive joint (5) and O-ring (6) and
remove them.

10 11
IFL312220031-02

9) Remove the pressure valve (12) and O-rings (13).

IFL312220027-02

12 12

5
13
IFL312220032-03
IFL312220028-01

7) Remove the manual release valve snap ring (7), Reassembly

then unscrew the manual release valve (8). Remove Assembly is reverse order of disassembly with special
seal washer (9). attention to following steps.

NOTE
• Do not reuse O-rings and seals once
8 removed.
Always use new parts.
• Lubricate all components and O-rings with
PTT fluid before assembly.
7 • Do not reuse PTT fluid, always refill with
new fluid.

IFL312220029-01

IFL312220030-02
 Power Trim and Tilt: 2B-17

PTT pump assembly Manual release valve

• Install the pressure valve (1) and O-rings (2). • Oil and install the manual release valve (1) and seal
washer (2).
Tighten the valve to specified torque.
• Install snap ring (3).
Tightening torque
Manual release valve (a): 1.7 N·m (0.17 kgf-m, 1.2
lbf-ft)

2
2
IFL312220033-03

1 (a)

1 1 IFL312220037-03

PTT motor and reservoir

• Ensure that the drive joint (1) is aligned and firmly
inserted into the gear pump assembly.
• Fit O-ring (2) to PTT motor.
IFL312220034-02

• Install the pump assembly (3), then tighten three

screws (4) to specified torque. 2

Tightening torque
Pump securing screw (a): 5 N·m (0.5 kgf-m, 3.6
lbf-ft)

1
IFL312220038-02

• Check the level of PTT fluid contained in the pump

and manifold assembly.
If level is low, add recommended PTT fluid until level
4 (a)
3 with mating surface of PTT motor.
• Ensure that the faces of the PTT motor and pump and
IFL312220035-01 manifold assembly are free of dirt or debris.
• Install the drive joint (5). When attaching the PTT motor to the pump and
manifold assembly, ensure that the tip of armature
shaft (3) fits firmly into the drive joint (1).

IFL312220036-01
2B-18 Power Trim and Tilt:

• Install the seal (4) and reservoir. 5) Connect the two extension cable lead wires (B to
• Tighten the screws (5) to specified torque. positive / R to negative) to the battery as shown in
the illustration.
Tightening torque Operate the PTT motor until the PTT rod is in the
PTT motor screw (a): 4.5 N·m (0.45 kgf-m, 3.3 lbf- fully trimmed down position (completely retracted).
ft) If the rod does not come down completely, push it in
by hand while operating the motor.

(A)
4

5 (a)
IFL312220039-02

PTT fluid
• Pour recommended PTT fluid into reservoir to IFL312220042-02

specified level. 6) Reverse the two extension cable lead wires (R to

Refer to “Checking PTT Fluid Level” (Page 2B-10). positive / B to negative).
Operate the PTT motor until the PTT rod is in the full
Air Bleeding tilt up position (fully extended).
Before installing the PTT unit on the outboard motor, use If the rod does not come up completely, pull it up by
the following procedure to bleed air from the system. hand while operating the motor.
1) Support the PTT unit in an upright position in a vise.
2) Fill the reservoir with PTT fluid to the specified level,
then install oil filler plug.
(A)

IFL312220041-02

7) Remove the reservoir oil filler plug and fill with PTT
fluid to the specified level.
8) Repeat procedures 5 – 7 until the fluid level in the
IFL312220040-01 PTT unit stabilizes at the specified level.
3) Tighten the manual release valve to the specified NOTE
torque.
Repeat the air bleeding procedure after the
4) Connect the PTT cable extension to the PTT motor
PTT unit has been installed on the outboard
cable connector.
motor.
Special tool Refer to “Air Bleeding from PTT Unit” (Page
(A): 09945–79410 (PTT cable extension) 2B-10).
 Power Trim and Tilt: 2B-19

Power Trim and Tilt Unit Components Cleaning • Inspect the pressure valve, and O-rings.
and Inspecting Replace if cut, nicks, excessive wear or other
CENFL3122206009 damages are found.
Arrange all components on a clean sheet of paper.

NOTE
• Do not lay PTT components out on a rag,
as dirt or lint may be transferred to these
items which may cause possible system
operating problems.
• If excessive wear, cracks, defective or
other damage is found on any component,
replace component.

• Inspect PTT pump assembly for cracks, nicks, and IFL312220046-01

any other imperfections.
• Inspect manual release valve for damage. Replace if
Replace if necessary.
necessary.
• Inspect O-rings for cuts, nicks or tears.

IFL312220043-01

• Inspect reservoir for cracks, nicks or damage.

IFL312220047-01
Replace if necessary.
• Inspect lower shaft and upper shaft for bends, twists
or other damage. Replace if necessary.
• Inspect all bushings for excessive wear or other
damage. Replace if necessary.
If bushing fit is loose when installing, replace bushing.

IFL312220044-01

• Inspect all O-rings for cuts, nicks or tears.

IFL312220048-01

IFL312220045-01
2B-20 Power Trim and Tilt:

Power Trim and Tilt Motor Disassembly and Assembly

Assembly Assembly is reverse of disassembly with special
CENFL3122206011 attention to following steps.
Disassembly
• Install O-ring (1).
1) For correct assembly, scribe an alignment mark on
• Install armature (2) to brush holder first. When
the field case and brush holder.
installing the armature, use care to avoid breaking the
2) Remove the two screws (1) securing the field case to brushes.
the brush holder.

1
2

IFL312220051-02
IFL312220049-01
• Install the field case.
3) Using a soft face hammer, gently tap the field case Match up previously scribed alignment marks.
(2) from side to side to unseat it from the brush
• Tighten screws securely.
holder.
Slide the field case (2) upward and away from the
brush holder.
Note the position of the O-ring (3) encircling the
brush holder.
Slide the armature (4) free of the brushes.

IFL312220052-01

PTT Motor Related Items Inspection

CENFL3122206012
Armature and Commutator
3 4 • Check for continuity between the commutator and the
IFL312220050-01
armature core / shaft.
Replace armature if continuity is indicated.
Special tool
(A): 09900–25008 (Multi circuit tester set)
Tester knob indication
Continuity ( )

(A)

I9J011220040-01
 Power Trim and Tilt: 2B-21

• Check continuity between adjacent commutator Commutator undercut

segments. Standard: 1.3 – 1.6 mm (0.05 – 0.06 in.)
Replace armature if no continuity is indicated. Service limit: 0.5mm (0.02 in.)

(A) “A”

“a”

“B”
I9J011220043-01

“A”: Segment “B”: Mica

Brushes
I9J011220041-01

• Inspect the commutator surface. • Check the length of each brush.

If surface is gummy or dirty, clean with 400 grit emery If brushes are worn down to the service limit, they
paper (1). must be replaced.
• Measure commutator outside diameter. Special tool
If measurement exceeds service limit, replace (B): 09900–20101 (Vernier calipers (150
armature. mm))
Special tool Brush length
(B): 09900–20101 (Vernier calipers (150 Standard: 9.8 mm (0.39 in.)
mm)) Service limit: 4.8 mm (0.19 in.)
Commutator outside diameter
Standard: 19.5 mm (0.77 in)
Service limit: 18.5 mm (0.73 in)

(B)

1
IFL312220054-03
(B)
O-ring
• Inspect the O-ring between the brush holder and field
I9J011220042-01
case.
• Ensure that the mica (insulator) between commutator Replace if cuts, nicks or tears are found.
segments are undercut “a” to specified depth.
If undercut is less than service limit, cut to specified
depth.

! WARNING
Failure to following proper precautions
during use of the compressed air may cause
severe personal injury.
Wear safety glasses when using compressed
air.

NOTE I9J011220045-01

Remove all particles of mica and metal using

compressed air.
2B-22 Power Trim and Tilt:

PTT Motor Relay Inspection NOTICE

CENFL3122206013
If the 12 V power supply wire is connected to
1) Disconnect all lead wire connectors from PTT motor
wrong terminal or touched to each other, the
relay (1).
power supply wire, tester may be damaged.
Remove the PTT motor relay from the electric parts
holder.
Be careful not to touch 12 V power supply
wires to each other or with other terminals.

3) Check continuity between terminal (3) and (5) each

time 12 V power supply is applied to terminal (1) and
1
(4).
Connect the positive (+) lead to terminal (1), and
negative (–) lead to terminal (4).
4) Check continuity between terminal (3) and (6) each
time 12 V power supply is applied to terminal (2) and
(4).
Connect the positive (+) lead to terminal (2), and
IFL312220053-02 negative (–) lead to terminal (4).
2) Check the resistance between each two terminals.
2 5 6
Special tool 1
(A): 09900–25008 (Multi circuit tester set)
Tester knob indication
Resistance (Ω)
PTT relay coil resistance
Between “terminal (1)” and “terminal (4)”: 16 – 24 3 4
Ω
Between “terminal (2)” and “terminal (4)”: 16 – 24
Ω

(A)
IFL312220065-01

1. Terminal 1 (UP coil) 4. Terminal 4 (GND)

2. Terminal 2 (DN coil) 5. Terminal 5 (For UP)
3. Terminal 3 (Power) 6. Terminal 6 (For DN)

Special tool
(A): 09900–25008 (Multi circuit tester set)
1 2 Tester knob indication
Continuity ( )

PTT relay function

4 Continuity
3 12 V power applied Yes
12 V power not applied No
(A)
5) If inspection in step 2 and/or step 3, 4 fails, replace
IDG211220027-03 PTT motor relay.
6) Install the PTT motor relay to the electric parts
holder.
 Power Trim and Tilt: 2B-23

PTT Switch Inspection

CENFL3122206014
Test continuity between the switch lead wires at each of 1
(W/R)
the three switch positions.
If out of specification, replace PTT switch. 2
(P) 3
Special tool (Lbl)
: 09900–25008 (Multi circuit tester set)
Tester knob indication
Continuity ( )
Tester probe connection Tester
Red (+) Black (–) indicates I9J011220048-02
DN side
Terminal (2) Terminal (1) Continuity
depressed 1 (Lg)
UP side 3 (Lbl)
Terminal (3) Terminal (1) Continuity
depressed
Not Terminal (2)
Terminal (1) Infinity 2 (R)
depressed Terminal (3)

I9J011220049-03
2B-24 Power Trim and Tilt:
 Table of Contents 3- i

Section 3

Lower Unit
CONTENTS

Precautions .................................................3-1 Lower Unit Removal and Installation...................3A-5

Precautions............................................................. 3-1 Water Pump Removal and Installation................3A-6
General Precautions ............................................. 3-1 Water Pump and Related Items Inspection.........3A-8
Precaution for Lower Unit ..................................... 3-1 Lower Unit Disassembly......................................3A-8
Pinion Bearing Removal and Installation ..........3A-11
Right Hand Rotation Unit........................ 3A-1 Lower Unit Related Items Inspection ................3A-13 3
Diagnostic Information and Procedures............3A-1 Propeller Shaft Oil Seal Replacement...............3A-16
Diagnose Lower Unit Malfunction ....................... 3A-1 Driveshaft Oil Seal Replacement ......................3A-16
Lower Unit Assembly ........................................3A-17
Service Instructions.............................................3A-2
Trim Tab Adjustment.........................................3A-22
Lower Unit Components ..................................... 3A-2
Lower Unit Gears - Shimming and
Propeller Removal and Installation ..................... 3A-4
Adjustment ......................................................3A-23
Propeller / Nut / Cotter Pin Inspection................. 3A-4
3-1 Precautions:

Precautions
Lower Unit

Precautions
General Precautions
CENFL3123000001
Refer to “General Precautions” in Section 00 (Page 00-1).

Precaution for Lower Unit

CENFL3123000002
! WARNING
Failure to take proper precautions when installing or removing the propeller can result in severe
personal injury.

When installing or removing the propeller:

• Shift into Neutral and remove the emergency stop switch lock plate so that the motor cannot be
started accidentally.
• Wear gloves to protect hands, and lock the propeller by placing a block of wood between the
propeller blade tips and the anti-cavitation plate before attempting to remove or install propeller nut.

! WARNING
Failure to take proper precautions when removing or installing the lower unit can result in severe
personal injury.

When installing or removing the lower unit:

• Always disconnect the battery cable, before removing lower unit.
• Remove the emergency stop switch lock plate from the emergency stop switch.

NOTE
• When draining lower unit gear oil, check the following points.
– Water ingress (white, milky appearance)
– Overheating or burning (black appearance, charred smell)
– Metal filings or deposits
• If reassembling with original components and gears, do not omit or add any shims or thrust
washers.
• To simplify reassembly and to prevent confusion, note the positions and quantities of all shims and
thrust washers. Retain these items next to the gears or bearings to which they belong.
 Right Hand Rotation Unit: 3A-1

Right Hand Rotation Unit

Lower Unit

Diagnostic Information and Procedures

Diagnose Lower Unit Malfunction
CENFL3123104001
Trouble Check Chart

Condition Possible cause Correction / Reference Item

Engine stalls when Idling speed set too low. Adjustment.
engaging gear Propeller shaft bearings damaged, Replace.
lacking lubrication or seized.
Engaging gear(s) has no Clutch out of adjustment. Adjustment.
effect on propulsion Driveshaft broken or splines damaged. Replace.
Chipped or worn dog clutches. Replace.
Propeller not secured correctly (fallen Inspection or retighten.
off).
Loss of power. (Assuming Propeller bush slipping. Replace.
engine is OK) Bent or worn propeller. Repair or replace.
Engine shakes the boat Failed propeller bush. Replace.
Bent driveshaft or propeller shaft. Replace.
Damaged propeller. Replace.
Clutch will not engage or Seized shift rod. Inspection.
disengage Clutch shaft and clutch rod have Inspection.
become detached.
Seized / broken remote control cable. Replace.
Problem at control box end. Inspection or replace.
3A-2 Right Hand Rotation Unit:

Service Instructions
Lower Unit Components
CENFL3123106001

2 1

4 6 34 (c)
5 7
8 33
9 32
10 14
12
11
13 15
17 31
16
19 (a)
20 (b) 35
18
36
23
21 37
24 30

22 29

26 25 28
27 (a)

IFL311310001-10

1. Shift rod 15. Exhaust seal plate 29. Under panel

2. Pin 16. Dowel pin 30. Water pump impeller
3. Boot 17. Anode 31. Water pump case
4. Stopper 18. Gasket 32. Stud bolt
5. Screw 19. Plug 33. Washer
6. Shift rod guide 20. Bolt 34. Nut
7. O-ring 21. Trim tab 35. Inner sleeve
8. O-ring 22. Bolt 36. O-ring
9. Washer 23. Water filter (STBD) 37. Key
10. Magnet 24. Water filter (PORT) : 5 N⋅m (0.5 kgf-m, 3.6 lbf-ft)
11. Holder 25. Screw : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft)
12. Pin 26. Gasket : 6 N⋅m (0.6 kgf-m, 4.3 lbf-ft)
13. Shift cam 27. Plug : Apply SUZUKI Silicone Seal.
14. Exhaust seal rubber 28. Gasket : Apply SUZUKI Water Resistant Grease.
 Right Hand Rotation Unit: 3A-3

37
10

9 (b)

36 (d)
35
34
5 8

32 33
7
29
6 30
26

3
31 (c)
28
2 27
25
23
24
1 (a)

11
20
18
16

22
21
17
19
13 14 15

12

IFL311310002-04

1. Nut 16. Thrust washer 31. Bolt

2. Pinion gear 17. Push pin 32. Stopper
3. Washer 18. Clutch dog shifter 33. Propeller
4. Collar 19. Dog pin 34. Spacer
5. Driveshaft 20. Dog spring 35. Washer
6. Thrust washer 21. Return spring 36. Nut
7. Bearing 22. Propeller shaft 37. Pin
8. Oil seal 23. Thrust washer : 18 N⋅m (1.8 kgf-m, 13.0 lbf-ft)
9. Oil seal housing 24. Reverse gear : 50 N⋅m (5.0 kgf-m, 36.0 lbf-ft)
10. O-ring 25. Shim : 10 N⋅m (1.0 kgf-m, 7.2 lbf-ft)
11. Bearing 26. O-ring : 25 N⋅m (2.5 kgf-m, 18.0 lbf-ft)
12. Bearing 27. Bearing : Apply SUZUKI Outboard Motor Gear Oil.
13. Push rod 28. Propeller shaft bearing housing : Apply SUZUKI Thread Lock 1342.
14. Shim 29. Bearing : Apply SUZUKI Water Resistant Grease.
15. Forward gear 30. Oil seal : Apply SUZUKI Silicone Seal.
3A-4 Right Hand Rotation Unit:

Propeller Removal and Installation Installation

CENFL3123106002
1) Coat the propeller shaft splines liberally with Suzuki
! WARNING water resistant grease.
Failure to take proper precautions when : Grease 99000–25350 (SUZUKI Water
installing or removing the propeller can Resistant Grease EP2 (250 g))
result in severe personal injury.
2) Install propeller stopper (1) onto propeller shaft, then
When installing or removing the propeller: slide on the propeller (2).
• Shift into “Neutral” and remove the 3) Fit spacer (3), washer (4) and nut (5), then tighten
emergency stop switch lock plate so that nut to specified torque.
the motor cannot be started accidentally. 4) Push cotter pin (6) through nut and shaft, then bend
• Wear gloves to protect hands, and lock the to secure.
propeller by placing a block of wood Tightening torque
between the propeller blade tips and the Propeller nut (a): 25 N·m (2.5 kgf-m, 18.0 lbf-ft)
anti-cavitation plate before attempting to
remove or install propeller nut. 2

Removal
1) Shift to “Neutral” position.
6
2) Remove cotter pin (1) from propeller nut and remove
1 5
propeller nut (2). 4
3) Remove washer (3), spacer (4), propeller (5) and 3
stopper (6) from the propeller shaft.

IFL311310004-02

(a)

I9J011310001-01

5
I9J011310003-04

Propeller / Nut / Cotter Pin Inspection

CENFL3123106003
1 Refer to “Propeller / Propeller Nut and Cotter Pin
6 2 Inspection” in Section 0B (Page 0B-18).
3
4

IFL311310003-02
 Right Hand Rotation Unit: 3A-5

Lower Unit Removal and Installation Installation

CENFL3123106004
Removal 1) Insert two dowel pins (1).
2) Apply water resistant grease to driveshaft splines.
! WARNING
: Grease 99000–25350 (SUZUKI Water
Failure to take proper precautions when Resistant Grease EP2 (250 g))
removing or installing the lower unit can
3) Apply a light coating of Suzuki silicone seal to mating
result in severe personal injury.
surfaces of gearcase and driveshaft housing.
Always disconnect the battery cable, before : Sealant 93691–80030 (SUZUKI Silicone
removing lower unit. Seal (100 g))

1) Shift to Neutral position.

Remove the bolt and trim tab (1) (if necessary).
1

1
IFL311310005-02

4) Slide the lower unit (2) into place, making sure that
the top of the driveshaft engages properly with the
IFL311310016-01 crankshaft and that water tube locates in the water
2) Loosen the clutch rod lock nut (2). pump case outlet.
3) To separate the clutch rod from the shift rod, Apply SUZUKI SILICONE SEAL to the retaining
unscrew the connector (3). bolts (3) and tighten them to specified torque.
: Sealant 93691–80030 (SUZUKI Silicone
Seal (100 g))
Tightening torque
Gearcase bolt (a): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

2
3 (a)

IFL311310017-04

4) Remove six bolts (4) and separate gearcase (5) from

driveshaft housing.
2

IFL311310019-01

5
IFL311310018-01
3A-6 Right Hand Rotation Unit:

5) Connect the clutch rod and the shift rod using the Water Pump Removal and Installation
clutch rod connector in the following procedure: CENFL3123106005
Removal
NOTE 1) Remove the lower unit. Refer to “Lower Unit
The clutch rod connector is not a turnbuckle Removal and Installation” (Page 3A-5).
but just a long nut with right-hand thread. 2) Loosen four nuts (1), then remove water pump case
(2).
a) Screw the clutch rod connector (4) onto the
clutch rod (5) all the way to the end of its thread.
b) Screw the lower nut (6) onto the shift rod (7) all
1
the way to the end of its thread.
c) Locate the shift cam at Neutral position by
moving shift rod (7) up or down and then hold it
at the position.
d) While holding the clutch lever (8), shift lever (9)
and shift cam at neutral position, screw the
clutch rod connector (4) onto the shift rod (7)
until the connector contacts the lower nut (6). 2
IFL311310021-01

5 5 3) Remove impeller (3), impeller key (4) and pump

under plate (5).
Keep impeller key (4) for reuse and discard the plate
4
4 gasket.

3
6 6

7 7

IAJ311310008-01

4
9
5
IFL311310022-01

NOTE
8 To facilitate the removal of inner sleeve from
pump case, warm up the entire case using a
heater like hair dryer.

IFL311310020-01
4) Remove O-ring (7) and inner sleeve (8) from pump
case.
e) With the clutch rod connector (4) securely held,
tighten the lower nut (6) firmly against the
connector.
f) Shift the shift lever from Neutral to Forward and
Reverse to check that the gear starts
engagement of both gears are at an equal angle
from Neutral.

8
7
IFL311310023-01
 Right Hand Rotation Unit: 3A-7

Installation 4) Place the O-ring (6) into position.

1) Place the under panel gasket (1) and under panel (2)
NOTE
into position.
Before installing water pump case assembly,
2) Insert the key (3) in the driveshaft and slide the
apply water resistant grease lightly on pump
impeller (4) onto driveshaft, ensuring that key and
case inner sleeve and under panel for initial
keyway is aligned.
lubrication.

: Grease 99000–25350 (SUZUKI Water

4 Resistant Grease EP2 (250 g))

6
3

2
1
IFL311310024-01

NOTE
• Before installing pump inner sleeve, apply IFL311310026-02
SUZUKI Bond 1207B lightly between inner
sleeve and pump case mating surfaces.
• Do not apply bond to inner sleeve top
surfaces.

3) Install inner sleeve (5) into the pump case, ensuring

that projection of inner sleeve and groove of pump
case are aligned.
: Sealant 99000–31140 (SUZUKI Bond
1207B (100 g))

IFL311310087-01
5 5) Install the pump case assembly (6) while rotating
driveshaft clockwise to flex the impeller vanes in the
correct direction.
Securely tighten the four pump case nuts (7) to the
specified torque.
Tightening torque
Water pump case nut (a): 6 N·m (0.6 kgf-m, 4.3
lbf-ft)
IFL311310025-01

NOTE 7 (a)

It is recommended that O-ring should be

replaced with new one on assembly.

6
IFL311310027-02

6) Install the Lower Unit. Refer to “Lower Unit Removal

and Installation” (Page 3A-5).
3A-8 Right Hand Rotation Unit:

Water Pump and Related Items Inspection Lower Unit Disassembly

CENFL3123106006 CENFL3123106007
Inspect the following parts. 1) Remove the lower unit. Refer to “Lower Unit
• Inspect impeller. Replace if vanes are cut, torn, worn Removal and Installation” (Page 3A-5).
or other abnormal conditions. 2) Remove the propeller. Refer to “Propeller Removal
• Inspect pump case. Replace if cracked, distorted or and Installation” (Page 3A-4).
other abnormal conditions are noted. 3) Remove the water pump and related parts. Refer to
• Inspect pump inner sleeve. Replace if worn, cracked, “Lower Unit Removal and Installation” (Page 3A-5)
distorted, corroded or other abnormal conditions are and “Water Pump Removal and Installation” (Page
noted. 3A-6).
• Inspect under panel. Replace if cracked, distorted, 4) Place a drain pan under oil drain plug. Remove oil
corroded or other abnormal conditions are noted. drain plug (1) first then oil level plug (2) and allow
• Check condition of O-ring. gear oil to drain.
Replace O-ring if nicked, cut, worn or other abnormal Inspect oil for water, contaminates or metal.
condition.
2

IFL311310030-01

IFL311310028-01 5) Remove the two bolts (3) securing the propeller shaft
bearing housing to the gearcase.

IFL311310029-01
IFL311310031-01
 Right Hand Rotation Unit: 3A-9

6) Using special tools, pull out the propeller shaft Special tool
bearing housing. (D): 09926–29400 (Driveshaft oil seal
Remove the propeller shaft and bearing housing housing remover)
assembly (4).
Special tool
(A): 09930–30104 (Sliding hammer)
(B): 09950–59310 (Propeller shaft remover) 7

(A)
(B)
(D)

IFL311310035-02

10) Lift out driveshaft (8).

4 Remove the driveshaft oil seal housing (7) from
driveshaft.
IFL311310032-01

7) Hold the pinion nut (5) securely, then fit special tool 8
to the driveshaft and loosen the pinion nut. Remove
pinion nut. 7
Special tool
(C): 09921–29511 (Driveshaft holder)

(C) IFL311310036-02

11) Remove the forward gear (9), back-up shim (10) and
5 bearing (11).

IFL311310033-02

8) Remove the water pump stud bolts (6).

11
10
6 6 9
IFL311310037-02

12) Remove the pinion gear (12) and pinion shim (13).

13
IFL311310034-01

9) Use special tool to unscrew driveshaft oil seal

housing (7), then remove oil seal housing from drive
shaft.
12

IFL311310038-01
3A-10 Right Hand Rotation Unit:

13) Remove the driveshaft collar (14).

14

18
20 19

21 17

IFL311310042-02

IFL311310039-01 b) Pull the push rod (22) out of the propeller shaft.
14) Remove the screws (15) securing the shift rod guide Remove spring (23) from clutch dog shifter (24).
stopper.
Pull out the shift rod assembly (16).

23
24
22
IFL311310043-02

15 c) Use special tool to push the dog pin (25) out of

IFL311310040-01 the clutch dog shifter (24).
Special tool
16 (E): 09922–89810 (Shift lock pin
remover)

(E)

25

IFL311310041-01

15) To disassemble propeller shaft components, refer to

following. 24
a) Slide propeller shaft away from reverse gear (17) IFL311310006-03

and bearing housing assembly (18). d) Remove clutch dog shifter (24), push pin (26)
Account for the reverse gear back-up shim (19) and return spring (27) from propeller shaft.
and reverse gear thrust washer (20).
Remove the forward gear thrust washer (21).
27
26

24

IFL311310044-02
 Right Hand Rotation Unit: 3A-11

16) To disassemble shift rod components, refer to Pinion Bearing Removal and Installation
following; CENFL3123106008
NOTICE
a) Remove the shift rod guide stopper (28).
Removing the bearing can cause damage to
needle rollers and outer race. If the removed
bearing is re-used, problem will occur in the
lower unit.

Do not reuse pinion bearings once removed.

Always use new ones.

Removal and Installation Tools

28 To remove the pinion bearing from the gearcase, use the
following special tools.

IFL311310045-03
Special tool
(A): 09951–59910 (Shaft (removal and
b) Remove the shift cam (29) from the shift rod (30)
installation))
by driving out the pin (31).
(B): 09951–39914 (Plate)
Remove the magnet holder (32), magnet (33)
(C): 01500–08403 (Bolt)
and pin (34).
(D): 09951–19440 (Attachment)
(E): 09930–30104 (Sliding hammer)

29

30

31
IFL311310046-02

IFL311310007-01
33

32

34

IFL311310047-02

c) Remove the washer (35), shift rod guide (36) and

dust boot (37).

36
35

37

IFL311310048-02
3A-12 Right Hand Rotation Unit:

Removal Installation
1) Disassemble the lower unit.
NOTE
Refer to “Lower Unit Disassembly” (Page 3A-8).
2) Remove the water pump stud bolts (1). • Before installing bearing, ensure that
inside of gearcase is clean and free of
debris.
• Ensure that the bearing stamped mark
faces upward.
1
1) Set the installer shaft (A), plate (B), attachment (D),
1 and pinion bearing as shown in the figure.
2) Place the installer shaft (A) (with pinion bearing on
end of installer shaft) into the gearcase.
3) Secure the plate (B) by tightening the bolt (C).
4) Thread the sliding hammer (E) into the top of the
IFL311310049-01 installer shaft (A).
3) Place the attachment (D) inside the pinion bearing. 5) Drive the pinion bearing down into position by gently
4) Insert the removal shaft (A) into attachment (D). striking the installer shaft (A) until the coupler
5) Thread sliding hammer (E) into top of removal shaft touches plate.
(A). 6) Assemble the lower unit.
6) Put wood block under pinion bearing. Refer to “Lower Unit Assembly” (Page 3A-17).
7) Drive the pinion bearing out downwards by striking
top of shaft (A) with sliding hammer (E). (E)

(A)

(E)

(C)
(A) (B)

IFL311310009-03

(A)
(D)
(D)
1 (E)

1
2
(B)
(C)

(A)
IFL311310008-01

1. Pinion bearing 2. Wood block (D)

IFL311310010-02

1. Pinion bearing
 Right Hand Rotation Unit: 3A-13

Lower Unit Related Items Inspection Gears / Bearing

CENFL3123106009
• Inspect forward, reverse and pinion gear teeth and
! WARNING engaging dogs.
Failure to following proper precautions Replace gears if damaged, worn or other abnormal
during use of the compressed air may cause conditions are noted.
severe personal injury. • Inspect forward gear bearing.
Replace bearing if pitted, noisy, rough or other
Wear safety glasses when using compressed abnormal conditions are noted.
air.

NOTE
• If any component is worn excessively,
cracked, defective or damaged in any way,
it must be replaced.
• Thoroughly wash all metal components
with cleaning solvent and dry with
compressed air.

Gearcase
IFL311310051-01
• Inspect the gearcase. Replace if cracked, damaged or
other abnormal conditions are noted. Propeller Shaft Components
• Visually check the pinion bearing. Replace bearing if • Inspect push rod and push pin.
pitted, rough or other abnormal conditions are noted. Replace if worn, damage or other abnormal condition
are noted.
NOTE
• Inspect clutch dog shifter. Replace if chipped, worn,
If removal and replacement are required, damaged or other abnormal conditions are noted.
refer to “Pinion Bearing Removal and
• Inspect dog pin. Replace if bent, worn or other
Installation” (Page 3A-11).
abnormal conditions are noted.
• Inspect propeller shaft/splines. Replace if worn,
twisted, damaged or other abnormal conditions are
noted.

IFL311310050-01

IFL311310052-01

IFL311310053-01
3A-14 Right Hand Rotation Unit:

• Check clutch return spring by measuring its free Shift Rod and Shift Cam Components
length. If free length is not within specifications, • Inspect the “stepped” surface of shift cam.
replace clutch return spring. Replace if worn, damaged or other abnormal
Clutch return spring free length “a” condition are noted.
Standard: 58.5 mm (2.30 in.) • Inspect shift rod guide.
Service limit: 56.5 mm (2.22 in.) Replace if cracked, damaged or other abnormal
conditions are noted.
“a” • Inspect O-ring. Replace if nicked, cut, torn, swollen or
other abnormal conditions are noted.
• Inspect dust boot. Replace if nicked, cut, worn or
other abnormal conditions are noted.
I9J011310062-01

Propeller Shaft Bearing Housing

• Inspect housing. Replace if cracked, damaged or
other abnormal conditions are noted.
• Inspect reverse gear bearing and propeller shaft
bearing. Replace bearing if pitted, noisy, rough or
other abnormal conditions are noted.
• Check condition of oil seal and O-ring. Replace oil
seal and O-ring if nicked, cut, worn or other abnormal
conditions are noted.
IFL311310055-01

IDG211310045-01
IFL311310056-01

IFL311310054-02
 Right Hand Rotation Unit: 3A-15

Driveshaft Oil Seal Housing Driveshaft

• Inspect housing. Replace if cracked, damaged or • Inspect driveshaft/splines. Replace if worn, twisted,
other abnormal conditions are noted. damaged or other abnormal conditions are noted.
• Check condition of oil seals. Replace if nicked, cut, • Inspect driveshaft bearing, replace if pitted, noisy,
worn or other abnormal conditions are noted. rough or other abnormal conditions are noted.
• Inspect O-ring. Replace if worn, nicked, cut or other
abnormal conditions are noted.

IFL311310059-02

IFL311310057-02

IFL311310060-02

IFL311310058-01
3A-16 Right Hand Rotation Unit:

Propeller Shaft Oil Seal Replacement Driveshaft Oil Seal Replacement

CENFL3123106010 CENFL3123106011
1) Remove the propeller shaft bearing housing. 1) Remove the driveshaft oil seal housing.
Refer to “Lower Unit Disassembly” (Page 3A-8). Refer to “Lower Unit Disassembly” (Page 3A-8).
2) Extract seals (1) with oil seal remover. 2) Using special tool, draw the two oil seals out of the
driveshaft oil seal housing.
NOTICE
Special tool
Removing the oil seal can cause damage to
(A): 09923–73210 (Bearing remover)
the seal lips, causing oil to leak.
Do not reuse the oil seal once removed. NOTICE
Always use new one.
Removing the oil seal can cause damage to
Special tool the seal lips, causing oil to leak.
(A): 09913–50121 (Oil seal remover) Do not reuse the oil seal once removed.
Always use new one.

(A)

1
(A)

IFL311310061-02

3) Apply water resistant grease to the inner IFL311310062-01

circumference of the housing.
3) Apply water resistant grease to inner circumference
: Grease 99000–25350 (SUZUKI Water of driveshaft oil seal housing.
Resistant Grease EP2 (250 g))
: Grease 99000–25350 (SUZUKI Water
4) Using an oil seal installer, drive the two oil seals (one Resistant Grease EP2 (250 g))
at a time) into the propeller shaft bearing housing.
4) Grease the inner lips of oil seal.
The lipped portion of the seals must face towards the
With the lips facing away from driveshaft bearing,
propeller. Apply water resistant grease to the seal
place seal in position and drive it into the oil seal
lips.
housing.

“A” “A”

IFL311310011-02
IFL311310012-04
“A”: Direction of propeller
“A”: Direction of driveshaft bearing

5) Assemble the propeller shaft bearing housing.

5) Assemble the driveshaft oil seal housing.
Refer to “Lower Unit Assembly” (Page 3A-17).
Refer to “Lower Unit Assembly” (Page 3A-17).
 Right Hand Rotation Unit: 3A-17

Lower Unit Assembly Driveshaft Collar

CENFL3123106012 Install the driveshaft collar (1).
Assembly is in reverse order of disassembly with special
attention to the following steps.

NOTICE 1

Failure to correctly adjust the gear position

will result in lower unit damage.
Before final assembly of lower unit, be
absolutely certain that all gear contact, shim
adjustments and tolerances are correct.
Refer to “Lower Unit Gears - Shimming and
Adjustment” (Page 3A-23).

NOTE IFL311310065-01

• Make sure that all parts used in assembly Driveshaft

are clean and lubricated. • Lower the driveshaft assembly (1) down into the
• It is recommended that all seals, gaskets gearcase until the bottom of shaft protrudes through
and O-rings be replaced with new on center of pinion gear.
assembly.
• After assembly, check parts for tightness
1
and smoothness of operation.

Pinion Gear
Place pinion gear (1) and pinion back-up shim (2) in
gearcase.

2
IFL311310066-01

IFL311310063-01

Forward Gear
Place the forward gear bearing (1) and back-up shim (2)
in position, then install forward gear (3).

1
3
2

IFL311310064-03
3A-18 Right Hand Rotation Unit:

Driveshaft Oil Seal Housing Pinion Nut

• Apply water resistant grease to the driveshaft oil seal. • Apply thread lock 1342 to the threads of pinion nut (1)
before threading it onto driveshaft.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g)) : Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
• Apply water resistant grease to O-ring (1), then install
O-ring into groove on the driveshaft oil seal housing • Tighten pinion nut to specified torque.
(2).
NOTE
It is recommended the original pinion nut be
used for the purposes of shimming during
repair. A new pinion nut should be used on
final assembly.

Special tool
(A): 09921–29511 (Driveshaft holder)
Tightening torque
Pinion nut (a): 18 N·m (1.8 kgf-m, 13.0 lbf-ft)
1
2
IFL311310067-05

• Install the driveshaft oil seal housing on the gearcase,

then tighten oil seal housing to specified torque.
Special tool (A)

(A): 09926–29400 (Driveshaft oil seal

housing remover) 1

Tightening torque
Driveshaft oil seal housing (a): 50 N·m (5.0 kgf-
m, 36 lbf-ft)
IFL311310069-02

Shift Cam and Shift Rod

• Apply water resistant grease to the shift rod guide O-
ring (1), (2) and the inside of the dust boot (3).
• Slide complete dust boot and shift rod guide (4) onto
the shift rod (5).
(A)
• Install the washer (6) and pin (7).
(a)
• Attach the magnet (8) and magnet holder (9) to shift
rod.
• Attach the shift cam (10) to shift rod, then insert the
IFL311310068-01
pin (11).

11 3 7

10 9 4 5
8 6
1
2
IFL311310070-02
 Right Hand Rotation Unit: 3A-19

• Attach the stopper (12) to the shift rod guide (4). Propeller Shaft
• Install shift rod assembly to the gearcase and secure
NOTE
stopper to gearcase with screws (13).
The clutch dog shifter is different between A/
NOTE AR/AT and AQ specification.
Be sure the stepped section “A” of shift cam To ensure consistent shift operation, never
faces towards propeller shaft. use the clutch dog shifter for A/AR/AT
specification to AQ.
An ID groove is provided at reverse side on
the AQ clutch dog shifter as shown figure.

12
“A” ID groove
4

IFL311310071-03

IFL312310002-01

• Slide the clutch dog shifter (2) onto the propeller shaft
(1).

NOTE
The side of the clutch dog shifter marked
with the letter “F” must face towards forward
gear.

NOTE
13 For AQ specification only;
IFL311310072-01 If you can not find the letter mark “F” on the
clutch dog shifter, the identification groove
Checking Driveshaft Thrust Play on the clutch dog shifter must face towards
Before installing reverse gear, driveshaft thrust play the reverse gear instead.
should checked.
Refer to “Lower Unit Gears - Shimming and Adjustment”
(Page 3A-23).
2
Special tool
(A): 09951–09530 (Gear adjusting gauge)
“F”

(A)
1

IFL311310074-02

IFL311310073-02
3A-20 Right Hand Rotation Unit:

• Insert the return spring (3), push pin (4) and push rod • Apply water resistant grease to the bearing housing
(5) into propeller shaft. O-ring (6).
Align the holes in the shifter dog and push pin.
Depress the push rod and slide the dog pin (6)
through both dog and push pin.

4
5

IFL311310078-02

6 NOTE
IFL311310075-01 Before installing the propeller shaft/bearing
• Install the dog pin retaining spring (7), ensuring that it housing assembly, bring the shift cam to the
fits snugly into the groove on the dog shifter. “Forward” position by moving shift rod up or
down.

• Using special tools, install the propeller shaft and

housing assembly in the gearcase.
Special tool
(A): 09922–59410 (Propeller shaft housing
installer)
(B): 09922–59420 (Housing installer handle)

7
(A)
IFL311310076-02

Propeller Shaft / Bearing Housing

• Place the forward thrust washer (1) and reverse thrust
washer (2) on the propeller shaft.
• Install back-up shim (3) and reverse gear (4) to
propeller shaft bearing housing (5).
(B)
• Slide propeller shaft into reverse gear and propeller
IDG211310073-01
shaft bearing housing.
• When the housing is fully seated, tighten both
: Gear Oil 99000–22B22 (SUZUKI Outboard retaining bolts to the specified torque.
Motor Gear Oil)
Tightening torque
Bearing housing bolt (a): 10 N·m (1.0 kgf-m, 7.2
3 lbf-ft)

(a)
5
4
IFL311310077-01

IFL311310079-01
 Right Hand Rotation Unit: 3A-21

Rechecking Driveshaft Thrust Play Leakage Check

Recheck the driveshaft thrust play. Check for leakage of oil seal and O-ring when applying
This should not be less than previously checked. specified pressure inside of the gearcase.
If less, reduce the number / thickness of the reverse gear 1) Install the test tool into the oil level hole.
back-up shims.
2) Connect the air pump to the tester.
Refer to “Lower Unit Gears - Shimming and Adjustment”
(Page 3A-23). 3) Rotate driveshaft and propeller shaft clockwise
several times and then apply specified pressure for
Special tool the test.
(A): 09951–09530 (Gear adjusting gauge)
NOTICE

(A)
Failure to correctly apply the test pressure
will result in oil seal damage.

Do not exceed pressure of 110 kPa (1.1 kg/

cm2, 15.6 psi.).

NOTE
Apply low initial pressure of 20 – 40 kPa (0.2
– 0.4 kg/cm2, 2.8 – 5.7 psi.) first, then apply
specified pressure.
IFL311310080-02

Special tool
Checking Propeller Shaft Thrust Play (A): 09950–69512 (Gearcase oil leakage
Check propeller shaft thrust play. tester)
Refer to “Lower Unit Gears - Shimming and Adjustment” (B): 09952–99320 (Hand air pump)
(Page 3A-23). (C): 09950–69710 (Attachment)
Special tool Leakage pressure test
(A): 09951–09530 (Gear adjusting gauge) 100 kPa (1.0 kg/cm2, 14.2 psi.)

(C)
(A)

IDG211310075-01
IFL311310081-02

(A)

(B)

(C)
IFL311310082-02

4) Once stabilized, pressure should remain steady for

at least 5 min.
If pressure does not fall, sealing performance is
correct.
3A-22 Right Hand Rotation Unit:

Water Pump Trim Tab Adjustment

Install the water pump and related parts. CENFL3123106013

Refer to “Lower Unit Removal and Installation” (Page The trim tab counteracts or minimizes propeller torque
3A-5) and “Water Pump Removal and Installation” (Page pull felt through the steering system.
3A-6). If the steering is pulls to the starboard or port side, adjust
the trim tab with the following procedure.
Propeller 1) Loosen the trim tab bolt (1).
Install the propeller.
Refer to “Propeller Removal and Installation” (Page 3A-
4). 1

Lower Unit
Install the Lower Unit.
Refer to “Lower Unit Removal and Installation” (Page
3A-5).

IFL311310013-01

2) Changing the trim tab setting.

• To compensate for a veer to starboard, set the
trailing edge of tab (2) to the right (as viewed from
behind).
• To compensate for a veer to port, set the trailing
edge of tab to the left.

I9J011310010-03

3) Tighten the bolt of trim tab.

4) Test drive the boat and repeat the procedure 1) – 3)
to set the trim tab in the best position.
With a properly adjusted trim tab, steering should be
neutral and there should be no tendency for the
steering to be pulled to either port or starboard.
 Right Hand Rotation Unit: 3A-23

Lower Unit Gears - Shimming and Adjustment

CENFL3123106014
If the lower unit has been rebuilt or has had components replaced, shimming for the correct gear contact and backlash
will have to be checked and/or adjusted to ensure smooth, reliable operation.
Shim / Washer and mounting position
Item Available thickness (mm) Design specification thickness (mm)
Pinion gear back up shim 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4 2.1
Forward gear back up shim 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5 1.2
Forward gear thrust washer 1.5 1.5
Propeller shaft reverse thrust washer 1.6, 1.8, 2.0, 2.2, 2.4, 2.6 1.8
Reverse gear back up shim 0.2, 0.5, 0.8 1.3

2
3

4
5
IFL311310014-02

1. Pinion gear back up shim 3. Forward gear thrust washer 5. Reverse gear back up shim
2. Forward gear back up shim 4. Propeller shaft reverse thrust washer
3A-24 Right Hand Rotation Unit:

Forward Gear / Pinion Gear Back-Up Shim

Adjustment
Follow the procedure below to adjust forward gear /
pinion gear.

Prior to adjustment
1) Correctly assemble driveshaft oil seal housing,
driveshaft, forward gear, pinion gear and related
components. Refer to “Lower Unit Assembly” (Page
3A-17).
Do not install reverse gear at this time.
2) Tighten pinion nut to specified torque. IAJ611310090-01

• If thrust play is larger than specified, the forward

Tightening torque
gear back-up shim thickness must be increased.
Pinion nut: 18 N·m (1.8 kgf-m, 13.0 lbf-ft)
• If thrust play is smaller than specified, the forward
gear back-up shim thickness must be decreased.

Checking and adjusting tooth contact pattern

(Pinion and Forward gear)
Check tooth contact pattern using the following
procedure.
1) To assess tooth contact, apply a light coat of
Prussian Blue on the convex surface of the forward
gear.
2) Install the propeller shaft and housing assembly
IFL311310083-01 (minus reverse gear and internal components).
3) Push the propeller shaft inward and hold it in
Checking driveshaft thrust play position.
1) Affix the gear adjusting gauge to driveshaft.
Special tool
(A): 09951–09530 (Gear adjusting gauge)
2) To check driveshaft thrust play, push the forward
gear inward and hold it in this position. Slowly push
the driveshaft downward completely, then slowly pull
the driveshaft up and read the maximum thrust play.
Driveshaft thrust play
0.3 – 0.6 mm (0.012 – 0.023 in.)

IAJ611310090-01
(A)
4) Using the driveshaft holder tool, rotate the driveshaft
5 – 6 times.
Special tool
(A): 09921–29511 (Driveshaft holder)

(A)
IFL311310084-07

IAJ611310091-01
 Right Hand Rotation Unit: 3A-25

5) Carefully remove the propeller shaft and housing to Example [A]

check the tooth contact pattern. Incorrect topside toe contact.
Correction measures.
“A” • Decrease thickness of forward gear shim.
“a”
“B” • Slightly increase pinion gear shim thickness.
“C”
NOTICE
“F” Setting the tooth contact in the top side toe
contact may cause damage and chipping on
“G”
“D” forward and pinion gears.
“E”
Do not set the tooth contact as such top side
toe contact.
I9J011310013-02

“A”: Concave side “E”: Tooth bottom

“B”: Convex side “F”: Toe Example of incorrect
“C”: Heel “G”: Tooth contact pattern
“D”: Tooth top “a”: Tooth width
“C”
Optimum tooth contact
The optimum tooth contact is shown in the figure. A shim “A”
adjustment may be necessary to obtain this contact I9J011310015-01

pattern.
Example [B]
NOTE Incorrect bottom side toe contact.
The driveshaft thrust play should be checked Correction measures.
when increasing or decreasing shim • Increase thickness of forward gear shim.
thickness to adjust tooth contact. • Slightly decrease pinion gear shim thickness.

NOTICE
Optimum tooth contact
Setting the tooth contact in the bottom side
“a” toe contact may cause chipping on pinion
“ b” gear.
“A” Do not set the tooth contact as such bottom
side toe contact.

“C”
Example of incorrect
“B”
IFL311310015-01

“A”: Heel “a”: Approx. 1/3 of tooth width

“B”: Convex side “b”: Approx. 1 mm
“C”
“C”: Toe
“A”
I9J011310016-01
3A-26 Right Hand Rotation Unit:

Rechecking driveshaft thrust play Reverse Gear Back-Up Shim Adjustment

After obtaining optimum tooth contact, driveshaft thrust After adjusting the forward gear tooth contact pattern,
play should be measured. follow the procedure below to adjust the reverse gear.
1) Affix the gear adjusting gauge to the driveshaft. 1) Correctly assemble and install reverse gear,
propeller shaft, propeller shaft bearing housing and
Special tool
related components.
(A): 09951–09530 (Gear adjusting gauge)
2) Screw a slide hammer assembly onto the propeller
2) To check driveshaft thrust play, push the forward shaft and strike it a few gentle outward taps.
gear inward and hold it in this position.
Push the driveshaft down completely, then slowly Special tool
pull the driveshaft up and read the maximum thrust (A): 09950–59310 (Propeller shaft remover)
play. (B): 09930–30104 (Sliding hammer)
Designate this amount of play as “A”.

NOTE
Driveshaft thrust play “A” must be known to
adjust reverse gear shim.

Driveshaft thrust play

0.3 – 0.6 mm (0.012 – 0.023 in.)

(A) (A)
(B)
IFL311310085-02

3) Affix the gear adjusting gauge to driveshaft.

Special tool
(C): 09951–09530 (Gear adjusting gauge)
4) Slowly push the driveshaft downward completely,
then slowly pull the driveshaft up and read the
maximum thrust play. Designate this measurement
as play “B”.
IFL311310084-07

(C)

IFL311310086-02

5) Compare play “B” to play “A”.

Refer to “Rechecking driveshaft thrust play” (Page
3A-26).
6) Reverse gear back-up shim adjustment is correct if
“B” is equal to “A”.
If “B” is less than “A”, reduce reverse gear back-up
shim thickness.
 Right Hand Rotation Unit: 3A-27

Checking propeller shaft thrust play 2) Push propeller shaft inward.

After adjusting all gear positions, measure the propeller 3) Hold the shaft in and set the dial gauge pointer to
shaft thrust play. If not within the following specification, zero.
a shim adjustment is required.
4) Slowly pull the shaft outward and read the maximum
NOTE thrust play on the dial gauge.
Maintain the forward gear thrust washer at • If the measurement is more than the specification,
standard thickness (1.5 mm) and use only the increase the propeller shaft reverse thrust washer
propeller shaft reverse thrust washer to thickness.
adjust thrust play. • If the measurement is less than the specification,
reduce the propeller shaft reverse thrust washer
Propeller shaft thrust play thickness.
Approx. 0.2 – 0.4 mm (0.01 – 0.02 in.)
1) Assemble the gear adjusting gauge to the propeller
shaft.
Special tool
(A): 09951–09530 (Gear adjusting gauge)

(A)

IAJ611310094-01
3A-28 Right Hand Rotation Unit:
 Table of Contents 4- i

Section 4

Wire / Hose Routing

CONTENTS

Precautions .................................................4-1 Wiring Diagram ...................................................4A-1

Precautions............................................................. 4-1 Wiring Harness Routing Diagram........................4A-7
Precautions for Wire / Hose Routing..................... 4-1
Fuel / Water Hose Routing ...................... 4B-1
Component Location ............................................. 4-1
Electrical Component Location ............................. 4-1 Precautions...........................................................4B-1
Precautions for Fuel / Water Hose Routing.........4B-1
Wire Routing ............................................ 4A-1 Schematic and Routing Diagram ........................4B-1
Schematic and Routing Diagram........................4A-1 Fuel/Water Hose Routing....................................4B-1

4
4-1 Precautions:

Precautions
Wire / Hose Routing

Precautions
Precautions for Wire / Hose Routing
CENFL3124000001
Refer to “General Precautions” in Section 00 (Page 00-1).

Component Location
Electrical Component Location
CENFL3124003001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-7).
 Wire Routing: 4A-1

Wire Routing
Wire / Hose Routing

Schematic and Routing Diagram

Wiring Diagram
CENFL3124102001
Refer to “Wire Color Symbols” in Section 0A (Page 0A-2).
 MAP W B/R
HIGH PRESSURE
R B/Y
SENSOR B B/W
FUEL PUMP
O/B
Gr #1
Br/Bl B/Br
THROTTLE R Gr #2
B FUEL INJECTOR
POSITION
R/W
SENSOR Gr #3
Gr
IAC VALVE W/B
4A-2 Wire Routing:

MAGNETO

Gr
DF25A/25AQ/30A/30AQ

CKP SENSOR

B/W B
R/B R/B

R/B
W/B
Br/Bl
W
O/B
B/Br
R/W
B/R
B/Y
B/W
Gr Gr
Y/Bl Y/Bl CMP SENSOR
O B
Bl
Bl/Y
ECM R
B
B/O
R/Y
Bl/O
G/W O O
G/Y
Bl/B
Y/B
Bl/W IGNITION COIL #1
Y/R
Lg/R
B
W W Y/W
RECTIFIER & W W Bl/Y
W W Bl O
REGULATOR
R R/Y
#1 B IGNITION COIL #2

R
Y
RECTIFIER & Y Bl/Y O
Y

Bl/Y Y
REGULATOR W
B
#2 CYLINDER TEMP. IGNITION COIL #3
W
SENSOR
FUSE 30A
B/O B
B B

B
Manual starter model

W B
Optional parts
B

WIRE COLOR
BATTERY B.......... Black BI/R......Blue with Red tracer
SDS Y
B Bl........ Blue BI/W......Blue with White tracer
SERVICE Gr
Y/R
CONNECTOR Br........ Brown BI/Y...... Blue with Yellow tracer
G........ Green Br/Bl..... Brown with Blue tracer
Gr........ Gray G/W..... Green with White tracer
OIL PRESSURE SWITCH O......... Orange G/Y...... Green with Yellow tracer
Bl/Y
29.4 9.8 kPa R.......... Red Lg/R..... Light green with Red tracer
(0.29 0.10 kgf/cm2, W......... White O/B...... Orange with Black tracer
B

4.18 1.39 psi) Y.......... Yellow R/B.......Red with Black tracer

ON B/Br......Black with Brown tracer R/W.......Red with White tracer
IAT
SENSOR B/O.......Black with Orange tracer R/Y.......Red with Yellow tracer
B
Lg/R B/R.......Black with Red tracer Y/B....... Yellow with Black tracer
NEUTRAL SWITCH
B/W...... Black with White tracer Y/Bl.......Yellow with Blue tracer
N ON
Br B B/Y....... Black with Yellow tracer Y/R.......Yellow with Red tracer
F,R OFF G Y/W
BI/B...... Blue with Black tracer Y/W...... Yellow with White tracer
BI/O......Blue with Orange tracer W/B..... White with Black tracer
TACHOMETER Y/B

Bl/B Bl/B
G/Y G/Y
INDICATOR G/W G/W
Gr Gr

EMERGENCY STOP & Bl Bl/W

ENGINE STOP SWITCH BZ Gr Gr

Lock plate IN or OFF RUN B B

Bl/R Bl/O
Lock plate OUT or ON STOP

IFL311410001-05
 MAP W B/R HIGH PRESSURE
R B/Y
SENSOR B B/W
FUEL PUMP
O/B
Gr #1
THROTTLE Br/Bl B/Br
POSITION R Gr #2
B FUEL INJECTOR
SENSOR R/W
Gr #3
Gr
IAC VALVE W/B

MAGNETO

Gr
CKP SENSOR

B/W B
R/B R/B

R/B
W/B
Br/Bl
W
O/B
B/Br
R/W
B/R
B/Y
B/W
Gr Gr
Y/Bl Y/Bl CMP SENSOR
O B
Bl
Bl/Y
ECM R
B
B/O
R/Y
Bl/O
G/W O O
G/Y
Bl/B
Y/B
Bl/W IGNITION COIL #1
Y/R
Lg/R
B
W W G
RECTIFIER & W W Bl/Y
W W Bl O
REGULATOR
R R/Y
#1 B IGNITION COIL #2

R
Y
RECTIFIER & Y Bl/Y O
Y
REGULATOR W R
B

G, Y/G Bl/Y, Y
#2 CYLINDER TEMP. IGNITION COIL #3
SENSOR

R
B
STARTER
B/O B
MOTOR B B

B
M
Electric starter model

R
BATTERY

Y
SDS B
Gr
SERVICE Y/R

CONNECTOR
Optional parts

R
R
FUSE 30A
R R R OIL PRESSURE SWITCH
Bl/Y
STARTER R/W Br 29.4 9.8 kPa
Bl/W G WIRE COLOR
RELAY (0.29 0.10 kgf/cm2,
B

B.......... Black BI/W......Blue with White tracer

4.18 1.39 psi)
ON Bl........ Blue BI/Y...... Blue with Yellow tracer
IAT Br........ Brown Br/Bl..... Brown with Blue tracer
SENSOR
B G......... Green G/W..... Green with White tracer
Lg/R
NEUTRAL SWITCH Gr........ Gray G/Y..... Green with Yellow tracer
N ON O......... Orange Lg/R..... Light green with Red tracer
Br B
F,R OFF G Y/G R.......... Red O/B...... Orange with Black tracer
START SWITCH
W/R W/R W......... White R/B.......Red with Black tracer
PUSH START Br Br
Y.......... Yellow R/W......Red with White tracer
TACHOMETER Y/B
B/Br......Black with Brown tracer R/Y...... Red with Yellow tracer
Bl/B Bl/B B/O.......Black with Orange tracer Y/B....... Yellow with Black tracer
G/Y G/Y
INDICATOR G/W G/W
Gr Gr B/R.......Black with Red tracer Y/Bl.......Yellow with Blue tracer
EMERGENCY STOP & Bl Bl/W
B/W...... Black with White tracer Y/G.......Yellow with Green tracer
BZ Gr Gr
ENGINE STOP SWITCH B/Y....... Black with Yellow tracer Y/R.......Yellow with Red tracer
B B BI/B...... Blue with Black tracer W/B..... White with Black tracer
Lock plate IN or OFF RUN Bl/R Bl/O
Wire Routing:

Lock plate OUT or ON STOP BI/O......Blue with Orange tracer W/R..... White with Red tracer
BI/R......Blue with Red tracer

IFL311410002-04
4A-3
 MAP W B/R
HIGH PRESSURE
R B/Y
SENSOR B B/W
FUEL PUMP
O/B
Gr #1
THROTTLE Br/Bl B/Br
POSITION R Gr #2
B FUEL INJECTOR
SENSOR R/W
Gr #3
Gr
IAC VALVE W/B
DF25ATH/30ATH
4A-4 Wire Routing:

MAGNETO

Gr
CKP SENSOR

B/W B
R/B R/B

R/B
W/B
Br/Bl
W
O/B
B/Br
R/W
B/R
B/Y
B/W
Gr Gr
Y/Bl Y/Bl CMP SENSOR
O B
Bl
ECM Bl/Y
R
B
B/O
R/Y
Bl/O
G/W O O
G/Y
Bl/B
Y/B
Bl/W IGNITION COIL #1
Y/R
Lg/R
B
W W G
RECTIFIER & W W Bl/Y
W W Bl O
REGULATOR
R R/Y
#1 B IGNITION COIL #2

R
Y
RECTIFIER & Y Bl/Y O
Y
REGULATOR W R
B
#2 CYLINDER TEMP. IGNITION COIL #3

W/R G, Y/G Bl/Y, Y

SENSOR

R
B
STARTER
B/O B

B
MOTOR B B

B
M

R
BATTERY

Y
SDS B
Gr
SERVICE Y/R

CONNECTOR

R
R
FUSE 30A OIL PRESSURE SWITCH Optional parts
R R R 29.4 9.8 kPa
Bl/Y
STARTER R/W Br (0.29 0.10 kgf/cm2,
Bl/W G
RELAY 4.18 1.39 psi) WIRE COLOR
B

ON
B
B.......... Black BI/O......Blue with Orange tracer
P B/W
IAT Lbl Bl........ Blue BI/W......Blue with White tracer
SENSOR R Br........ Brown BI/Y...... Blue with Yellow tracer
B B M
Lg/R
B

NEUTRAL SWITCH G......... Green Br/Bl..... Brown with Blue tracer

N ON Gr........ Gray G/W..... Green with White tracer
Br B PTT RELAY PTT MOTOR
F,R OFF G Y/G Lbl........ Light blue G/Y..... Green with Yellow tracer
START SWITCH
W/R W/R O......... Orange Lg/R..... Light green with Red tracer
PUSH START Br Br
P.......... Pink O/B...... Orange with Black tracer
TACHOMETER Y/B R.......... Red R/B.......Red with Black tracer
Bl/B Bl/B W......... White R/W......Red with White tracer
G/Y G/Y
INDICATOR G/W G/W Y.......... Yellow R/Y...... Red with Yellow tracer
Gr Gr

EMERGENCY STOP & B/Br......Black with Brown tracer Y/B....... Yellow with Black tracer
Bl Bl/W
BZ Gr Gr B/O.......Black with Orange tracer Y/Bl.......Yellow with Blue tracer
ENGINE STOP SWITCH
B B B/R.......Black with Red tracer Y/G.......Yellow with Green tracer
Lock plate IN or OFF RUN Bl/R Bl/O
Lock plate OUT or ON STOP B/W...... Black with White tracer Y/R.......Yellow with Red tracer

UP
Lbl
Lbl B/Y....... Black with Yellow tracer W/B..... White with Black tracer
W/R W/R
PTT SWITCH P BI/B...... Blue with Black tracer W/R..... White with Red tracer
P

DN

IFL311410003-04
 MAP W B/R HIGH PRESSURE
R B/Y
SENSOR B B/W FUEL PUMP
O/B
DF25AR

Gr #1
THROTTLE Br/Bl B/Br
R Gr #2 FUEL INJECTOR
POSITION B
SENSOR R/W
Gr #3
Gr
IAC VALVE W/B

Optional parts
MAGNETO

Gr
WIRE COLOR
CKP SENSOR
B.......... Black B/Br......Black with Brown tracer O/B...... Orange with Black tracer

R
Bl......... Blue B/O.......Black with Orange tracer P/G...... Pink with Green tracer
Br........ Brown B/R.......Black with Red tracer R/B.......Red with Black tracer
G........ Green B/W...... Black with White tracer R/W.......Red with White tracer B/W B
Gr........ Gray B/Y....... Black with Yellow tracer R/Y.......Red with Yellow tracer R/B R/B

Lbl........ Light blue BI/B...... Blue with Black tracer Y/B....... Yellow with Black tracer R/B
W/B
O......... Orange BI/O......Blue with Orange tracer Y/Bl.......Yellow with Blue tracer Br/Bl
W
P.......... Pink BI/W......Blue with White tracer Y/G.......Yellow with Green tracer O/B
B/Br
R/W
R.......... Red BI/Y...... Blue with Yellow tracer Y/R.......Yellow with Red tracer B/R
B/Y
W......... White Br/Bl..... Brown with Blue tracer W/B..... White with Black tracer B/W
Gr Gr
Y/Bl Y/Bl CMP SENSOR
Y.......... Yellow G/W..... Green with White tracer W/R..... White with Red tracer O B
Bl
G/Y...... Green with Yellow tracer W/Y..... White with Yellow tracer Bl/Y
R
ECM B
Lg/R..... Light green with Red tracer B/O
R/Y
Bl/O
G/W O O
G/Y
Bl/B
Y/B
Bl/W IGNITION COIL #1
Y/R
Lg/R
B
W W G
RECTIFIER & W W Bl/Y
W W P/G Bl O
REGULATOR
R R/Y
#1 B IGNITION COIL #2
LIGHTING R/G
Y
B RECTIFIER & Y Bl/Y O
SWITCH Gr Y
B REGULATOR W R

G/Y G, Y/G Bl/Y, Y

B
R/G #2 CYLINDER TEMP. IGNITION COIL #3
B

Bl/B
SENSOR

B
R/G
Gr Gr

R
B
METER STARTER

R/G
B B B/O B
MOTOR B B

B
R/G
B BATTERY M

R/G
B
R/G
Gr Gr TRIM W/Y W/Y
B B B B
METER

R/G R/G
B B
Y
SDS B
Gr Gr Gr
TACHOMETER Bl/B Bl/B SERVICE Y/R
B B
G/Y G/Y
Y Y P P CONNECTOR
WITH LED G/W G/W

R
R
FUSE 30A OIL PRESSURE SWITCH
10A Bl/Y
R R R 29.4 9.8 kPa
STARTER R/W Br
Bl/W G (0.29 0.10 kgf/cm2,
RELAY
B

4.18 1.39 psi)

FUSE 10A ON
IAT Gr Gr

SENSOR
B
NEUTRAL Lg/R

PUSH FREE ST IG OFF SWITCH

IGNITION N ON
GND B Br B
SWITCH G Y/G
STOP G
F,R OFF
BATT W

IG Gr

SUZUKI
W/Y
START Br B
Bl/B Bl/B
B.Z O G/Y G/Y
Lbl P P/G
EMERGENCY STOP SWITCH RESET W/R G/W G/W
P Lbl
Lock plate IN RUN PUSH TURN P
O O O
Lock plate OUT STOP Gr Gr Bl Bl
W W W P
BZ Br Br Br Br
W/R W/R Y Y/B
G G G Bl/O
G G Gr Gr Gr Gr Bl/B Bl/B
B B Bl Bl/W Bl/W Bl/W G/Y G/Y
B B B B G/W G/W
Wire Routing:

Gr Gr

INDICATOR

IFL311410021-03
4A-5
 MAP W B/R HIGH PRESSURE
R B/Y
SENSOR B B/W FUEL PUMP
O/B
Gr #1
THROTTLE Br/Bl B/Br
POSITION R Gr #2 FUEL INJECTOR
B
SENSOR R/W
Gr #3
DF25AT/30AT

Gr
IAC VALVE W/B

Optional parts
4A-6 Wire Routing:

MAGNETO

Gr
WIRE COLOR
B.......... Black B/Br.......Black with Brown tracer O/B...... Orange with Black tracer CKP SENSOR

R
Bl........ Blue B/O.......Black with Orange tracer P/G...... Pink with Green tracer
Br........ Brown B/R.......Black with Red tracer R/B.......Red with Black tracer
G......... Green B/W...... Black with White tracer R/G.......Red with Green tracer
B/W B
Gr........ Gray B/Y....... Black with Yellow tracer R/W......Red with White tracer R/B R/B

Lbl........ Light blue BI/B...... Blue with Black tracer R/Y...... Red with Yellow tracer
R/B
O......... Orange BI/O......Blue with Orange tracer Y/B....... Yellow with Black tracer W/B
Br/Bl
P.......... Pink BI/W......Blue with White tracer Y/Bl.......Yellow with Blue tracer W
O/B
B/Br
R.......... Red BI/Y...... Blue with Yellow tracer Y/G.......Yellow with Green tracer R/W
B/R
W......... White Br/Bl..... Brown with Blue tracer Y/R.......Yellow with Red tracer B/Y
B/W
Gr Gr
Y.......... Yellow G/W..... Green with White tracer W/B..... White with Black tracer Y/Bl Y/Bl CMP SENSOR
O B
G/Y...... Green with Yellow tracer W/R..... White with Red tracer Bl
Bl/Y
ECM R
Lg/R..... Light green with Red tracer W/Y..... White with Yellow tracer B
B/O
R/Y
Bl/O
G/W O O
G/Y
Bl/B
Y/B
Bl/W IGNITION COIL #1
Y/R
Lg/R
B
W W G
RECTIFIER & W W Bl/Y
W W P/G Bl O
REGULATOR
R R/Y
#1 B IGNITION COIL #2

Bl/Y
LIGHTING R/G
Y
B RECTIFIER & Y Bl/Y O
SWITCH Gr Y
B REGULATOR W R

P G Y/G
B
R/G #2 CYLINDER TEMP. IGNITION COIL #3
B

Lbl
SENSOR

B
R/G
Gr Gr

R
B
METER STARTER

R/G
B B B/O B
MOTOR B B

B
R/G
B BATTERY M

R/G
B
R/G
Gr Gr TRIM W/Y W/Y
B B B B
METER

R/G R/G
B B
Y
SDS B
Gr Gr Gr
TACHOMETER Bl/B Bl/B SERVICE Y/R
B B
G/Y G/Y
Y Y P P CONNECTOR
WITH LED G/W G/W

R
R
OIL PRESSURE SWITCH
10A
FUSE 30A Bl/Y 29.4 9.8 kPa
R R R
R/W Br
(0.29 0.10 kgf/cm2,
PTT SWITCH STARTER Bl/W G
4.18 1.39 psi)
RELAY
B

DN UP
ON
FUSE 10A
B
Gr Gr P B/W
IAT Lbl
SENSOR R
B B M
NEUTRAL Lg/R
B

PUSH FREE ST IG OFF SWITCH

IGNITION N ON PTT MOTOR
GND B Br B PTT RELAY
SWITCH G Y/G Lbl
UP

STOP G
F,R OFF
Lbl
W/R W/R
BATT W P
Bl/B G/Y G/W R, W/R

P
DN

IG Gr

SUZUKI
W/Y W/Y W/Y W/Y
START Br B B/W B/W B PTT SWITCH
Bl/B Bl/B
B.Z O G/Y G/Y
Lbl Lbl P P/G
EMERGENCY STOP SWITCH RESET W/R W/R G/W G/W
P P Lbl Lbl
Lock plate IN RUN PUSH TURN P P
O O O
TRIM SENDER
Lock plate OUT STOP Gr Gr Bl Bl
W W W R
BZ Br Br Br Br
W/R W/R Y Y/B
G G G Bl/O
G G Gr Gr Gr Gr Bl/B Bl/B
B B Bl Bl/W Bl/W Bl/W G/Y G/Y
B B B B G/W G/W
Gr Gr

INDICATOR

IFL312410001-01
 Wire Routing: 4A-7

Wiring Harness Routing Diagram

CENFL3124102002
Manual Starter Model

“B”

1 “A”

IFL311410004-06

1. Clamp “B”: Make sure that main harness not to ride on the guide.
: Clamp main harness with fuel hose.
“A”: Pass the main harness from mating surface of intake manifold to engine side.

1 4

3 “B”
1 2 (a)
4

“A”

IFL311410005-02

1. Ignition coil “A”: Contacts the lead wire terminal lightly to ignition coil.
2. Bolt “B”: Rib part of fuel delivery pipe
: Tighten with ignition coil and its GND lead wire.
3. Harness : 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft)
4. Clamp
: Clamp the harness along with rib of fuel delivery pipe.
4A-8 Wire Routing:

7
7

4
11
4
(a)
1

5 2 3
“a”

12

6
9

11 “A”
8 10 (b)
“B”
IFL311410006-08

1. CMP sensor 10. Oil pressure switch

: Cover the oil pressure switch with cap.
2. Main harness 11. Washer
3. Clamp 12. Clamp
: Contacts clamp lightly to CMP sensor. : Pass the main harness the back of high tension cords.
4. Main harness GND lead wire “A”: Contacts main harness GND lead wire lightly to electric parts holder.
5. IAT sensor “B”: Fix the oil pressure switch lead wire horizontally.
6. Clamp : 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft)
7. Bolt : 13 N⋅m (1.3 kgf-m, 9.5 lbf-ft)
: Tighten with electric parts holder and main harness GND lead wire.
8. Stator GND lead wire “a”: 20 – 30 mm (0.79 – 1.18 in)
9. Bolt
: Tighten with electric parts holder and stator GND lead wire.
 Wire Routing: 4A-9

2 3 4 (b)

“A”

5 15
“a”
(a) “B”
1
14

10 12 1 6
8
9 13

7
11
IFL311410007-06

1. CKP sensor 11. Neutral switch connector (lower)

: Set the lock part of connector upward.
2. MAP sensor 12. Indicator lamp connector
: Set the lock part of connector upward.
3. Clamp 13. Buzzer connector
: Install the clamp as shown.
4. Cylinder temperature sensor 14. Clamp
5. Joint connector 15. CMP sensor
: Fix joint connector with the hooks.
6. ECM “A”: Put main harness along the guides.
7. ECM cushion “B”: Put cylinder temp. sensor lead wire along the guides.
8. Electric parts holder : 5 N⋅m (0.5 kgf-m, 3.5 lbf-ft)
9. Connector holder : 9 N⋅m (0.9 kgf-m, 6.5 lbf-ft)
10. Emergency stop switch connector (upper) “a”: 5 – 15 mm (0.2 – 0.6 in.)
: Set the lock part of connector upward.
4A-10 Wire Routing:

2 1

4
3

“A”

5
6
5
5
Reverse side
(a)
IFL311410008-04

1. Indicator lamp 5. Emergency stop switch

2. Shift rod 6. Lock plate
3. Emergency stop switch lead wire “A”: Route the emergency stop switch lead wire along wall of handle.
4. Throttle cable : 2 N⋅m (0.2 kgf-m, 1.5 lbf-ft)

1 3
2
5

“A”

IFL311410009-03

1. CKP sensor 5. CKP sensor connector

: Set the lock part of connector outside.
2. Clamp 6. Power source coil lead wire
: Fix the power source coil lead wire to electric parts holder with clamp. : Pass the power source coil lead wire through guides.
3. CKP sensor lead wire 7. Dummy connector
: Pass the CKP sensor lead wire through the guide.
4. Cylinder temp. sensor connector “A”: Fix the power source connector from back side to electric parts holder.
: Set the lock part of connector outside.
 Wire Routing: 4A-11

Electric Starter Model

“B”

“A”
1

IFL311410010-05

1. Clamp “B”: Make sure that main harness not to ride on the guide.
: Clamp main harness with fuel hose.
“A”: Pass the main harness from mating surface of intake manifold to engine side.

1 4

3 “B”
1 2 (a)
4

“A”

IFL311410011-02

1. Ignition coil “A”: Contacts the lead wire terminal lightly to ignition coil.
2. Bolt “B”: Rib part of fuel delivery pipe
: Tighten with ignition coil and its GND lead wire.
3. Harness : 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft)
4. Clamp
: Clamp the harness along with rib of fuel delivery pipe.
4A-12 Wire Routing:

21
21

12 7
(c)
(c)
20
12 7
(a) 1
16
11
14 13 14
15 15
2 3
“a”
5
4

19
6
9
18

“A”
20 10 (b)
8 17
“B”

DF25A/25AQ/25AR/30A/30AQ
IFL312410002-01

1. CMP sensor 15. Starter motor cable

: Put back side of the cables together.
2. Main harness 16. Cap
: Cover the terminals with the cap.
3. Clamp 17. Bracket
: Contacts clamp lightly to CMP sensor.
4. Clamp 18. Rectifier/regulator No.1
: Pass the main harness the back of high tension cords.
5. IAT sensor 19. Rectifier/regulator No.2
6. Clamp 20. Washer
7. Main harness GND lead wire 21. Bolt
: Tighten with electric parts holder and main harness GND lead wire.
8. Stator GND lead wire “A”: Contacts main harness GND lead wire lightly to electric parts holder.
9. Bolt “B”: Fix the oil pressure switch lead wire horizontally.
: Tighten with electric parts holder and rectifier/regulator GND lead wire.
10. Oil pressure switch : 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft)
: Cover the oil pressure switch with cap.
11. Starter motor : 13 N⋅m (1.3 kgf-m, 9.5 lbf-ft)
12. Starter relay : 3.5 N⋅m (0.35 kgf-m, 2.5 lbf-ft)
13. Starter motor sub cable “a”: 20 – 30 mm (0.79 – 1.18 in)
14. Main harness
 Wire Routing: 4A-13

21

21
12 7
(c) 20
12 (c)
7
(a) 1
16
14 11
14
15 13
15
2 3
“a”
5
4

6 19

9
18
9

20 “A”
8
10 (b) 17
“B”
DF25ATH/25AT/30ATH/30AT
IFL312410003-01

1. CMP sensor 15. Starter motor cable

: Put back side of the cables together.
2. Main harness 16. Cap
: Cover the terminals with the cap.
3. Clamp 17. Bracket
: Contacts clamp lightly to CMP sensor.
4. Clamp 18. Rectifier/regulator No.1
: Pass the main harness the back of high tension cords.
5. IAT sensor 19. Rectifier/regulator No.2
6. Clamp 20. Washer
7. Main harness GND lead wire 21. Bolt
: Tighten with electric parts holder and main harness GND lead wire.
8. Stator GND lead wire “A”: Contacts main harness GND lead wire lightly to electric parts holder.
9. Bolt “B”: Fix the oil pressure switch lead wire horizontally.
: Tighten with electric parts holder and rectifier/regulator GND lead wire.
10. Oil pressure switch : 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft)
: Cover the oil pressure switch with cap.
11. Starter motor : 13 N⋅m (1.3 kgf-m, 9.5 lbf-ft)
12. Starter relay : 3.5 N⋅m (0.35 kgf-m, 2.5 lbf-ft)
13. Starter motor sub cable “a”: 20 – 30 mm (0.79 – 1.18 in)
14. Main harness
4A-14 Wire Routing:

4
(a)

“a”

3 2

5
“a”

DF25A/25AQ/25AR/30A/30AQ
IFL311410013-07

1. Starter motor 5. Bolt

: Tighten with starter motor GND lead wire.
2. Damper : 3.5 N⋅m (0.35 kgf-m, 2.5 lbf-ft)
3. Starter motor band “a”: 45° ± 10°
4. Starter motor sub cable

4
(a)

“a”

3 2

5
“a”

DF25ATH/25AT/30ATH/30AT
IFL311410019-05

1. Starter motor 5. Bolt

: Tighten with starter motor GND lead wire.
2. Damper : 3.5 N⋅m (0.35 kgf-m, 2.5 lbf-ft)
3. Starter motor band “a”: 45° ± 10°
4. Starter motor sub cable
 Wire Routing: 4A-15

3
2
1

“A”
6 8

7 (a) “B”
1 4 (b)

17 17 17 17
16 16 16 16

9 “C” 9 9 “C” 9
“C” “C”

10 10 10 10
13
13 15 15

11 11 18
12, 14 18 12, 14
DF25A/25AQ/30A/30AQ DF25AR DF25ATH/30ATH DF25AT/30AT
IFL311410015-04

1. CKP sensor 13. Buzzer connector

2. MAP sensor 14. Starter switch connector (upper)
: Set the lock part of connector upward.
3. Clamp 15. Remote control connector
: Install the clamp as shown.
4. Cylinder temperature sensor 16. Clamp
5. Joint connector 17. Starter cable
: Fix joint connector with the hooks.
6. ECM 18. PTT switch connector
7. ECM cushion “A”: Put main harness along the guides.
8. Electric parts holder “B”: Put cylinder temp. sensor lead wire along the guides.
9. Connector holder “C”: Put starter cable along the guide.
10. Emergency stop switch connector (upper) : 5 N⋅m (0.5kgf-m, 3.5 lbf-ft)
: Set the lock part of connector upward.
11. Neutral switch connector (lower) : 9 N⋅m (0.9 kgf-m, 6.5 lbf-ft)
: Set the lock part of connector upward.
12. Indicator lamp connector (lower)
: Set the lock part of connector upward.
4A-16 Wire Routing:

DF25A/25AQ/30A/30AQ
DF25AR/25AT/30AT
2 5 1

4 4
6 9
3
6

“B”

“A”

7
8
7 7

Reverse side
(a)
IFL311410014-06

1. Indicator lamp 7. Emergency stop switch

2. Shift rod 8. Lock plate
3. Emergency stop switch lead wire 9. Remote control cable
4. Throttle cable “A”: Route the emergency stop switch lead wire along wall of handle.
5. Starter switch “B”: Set the cut portion of clamp to bracket side.
6. Starter cable : 2 N⋅m (0.2kgf-m, 1.5 lbf-ft)

DF25ATH/30ATH
DF25AR/25AT/30AT
2 5 1

12
4 4
6 9
3
6

11

“B”
“A”
10
7
8
7
7
10 Reverse side
(a)

IFL311410020-03

1. Indicator lamp 9. Remote control cable

2. Shift rod 10. PTT switch holder
3. Emergency stop switch lead wire 11. PTT switch
4. Throttle cable 12. PTT motor cable
5. Starter switch “A”: Route the emergency stop switch lead wire along wall of handle.
6. Starter cable “B”: Set the cut portion of clamp to bracket side.
7. Emergency stop switch : 2 N⋅m (0.2kgf-m, 1.5 lbf-ft)
8. Lock plate
 Wire Routing: 4A-17

1 6
7 1

5 2
3
“A” 5

1
4
(a) 9
8
10
11

7
IFL311410016-03

1. Electric parts holder 8. ECM connector

2. Main harness 9. Clamp
3. Diode (except for manual start model) 10. Starter relay
4. Condenser 11. Dummy plug (except for remote control model)
5. SDS service connector “A”: Pass the SDS service connector and fuse box lead wires above the hook.
6. Cap : 3.5 N⋅m (0.35 kgf-m, 2.5 lbf-ft)
: Fit the hole of cap with projection of connector.
7. Fuse case (except for manual start model)

1
7

3
5
2

4
8 6

IFL311410017-01

1. CKP sensor 5. CKP sensor connector

: Set the lock part of connector outside.
2. Clamp 6. Battery charge coil lead wire
: Fix the battery charge coil lead wire to electric parts holder with clamp. : Pass the battery charge coil lead wire along guides.
3. CKP sensor lead wire 7. Rectifier/regulator No.1 connector
: Pass the CKP sensor lead wire along the guide.
4. Cylinder temp. sensor connector 8. Rectifier/regulator No.2 connector
: Set the lock part of connector outside.
4B-1 Fuel / Water Hose Routing:

Fuel / Water Hose Routing

Wire / Hose Routing

Precautions
Precautions for Fuel / Water Hose Routing
CENFL3124200001
Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions on Fuel System Service” in Section 1G
(Page 1G-1).

Schematic and Routing Diagram

Fuel/Water Hose Routing
CENFL3124202001

3 5 4

2
“a” 1
3
“a” 1 2

“a”

14

12
8
13
9 5
11
10
15
17
7 16
IFL311420005-02

1. Intake manifold assembly 7. Water hose (driveshaft housing to fuel cooler) 13. Fuel feed hose
2. MAP sensor 8. Water hose (fuel cooler to driveshaft housing) 14. Fuel delivery pipe
3. Fuel hose (low pressure fuel pump to fuel vapor separator) 9. Fuel hose (fuel cooler to in-line fuel filter) 15. Fuel drain hose No.1
4. Fuel vapar separator 10. In-line fuel filter 16. Fuel drain body
5. Evaporation hose 11. Fuel hose (in-line fuel filter to high pressure fuel pump) 17. Fuel drain hose No.2
6. Fuel injector 12. High pressure fuel pump “a”: 55°
 Fuel / Water Hose Routing: 4B-2

20
4 4
2 5
1 3 1 5
4
14
15

16
6
7 13
9
13 13
6
12 10
11
17
18
19 9 8
IFL311420006-02

1. Intake manifold assembly 11. In-line fuel filter

2. MAP sensor 12. Fuel hose (in-line fuel filter to high pressure fuel pump)
3. IAC valve air outlet hose 13. High pressure fuel pump
4. Fuel hose (low pressure fuel pump to fuel vapor separator) 14. Fuel vapar hose: Connect yellow marking side of the hose to fuel vapor separator.
5. Fuel vapar separator 15. Fuel return hose: Connect white marking side of the hose to fuel vapor separator.
6. Fuel hose (fuel vapor separator to fuel cooler) 16. Hose clamp: Attach the clamp onto white marking part of fuel return hose.
7. Fuel cooler 17. Fuel drain hose No.1
8. Water hose (driveshaft housing to fuel cooler) 18. Fuel drain body
9. Water hose (fuel cooler to driveshaft housing) 19. Fuel drain hose No.2
10. Fuel hose (fuel cooler to in-line fuel filter) 20. Evaporation hose

“6”

“5”
“1”
3
“2”
“4”
“3” “A”

7 1
8 “9”
“7” 2
4
5 6
“8” “10”
View “A”

IFL311420001-03

1. Exhaust manifold 5. Anode protection bolt

: When installing the exhaust manifold to the engine, tighten the bolts in numerical order.
2. Exhaust manifold plug 6. Anode protection
3. Exhaust manifold plug 7. O-ring
4. Gasket 8. Anode protection cover
4B-3 Fuel / Water Hose Routing:

“A”

IFL311420002-02

1. Cylinder head cover 6. Fuel hose (low pressure fuel filter to low pressure fuel pump)
2. Low pressure fuel filter 7. Fuel hose (low pressure fuel pump to fuel vapor separator)
3. Low pressure fuel filter clamp 8. Hose clamp
4. Low pressure fuel pump “A”: Insert the boss of filter into the hole of clamp.
5. O-ring
 Fuel / Water Hose Routing: 4B-4

4 3 2 1

8
7
9

6 5 3

10

11

12
13

14

15

16

17
21
18 “A”
22
19 24
25
23 26 22

View “A”

20

IFL311420003-06

1. Intake manifold assembly 10. Breather hose 19. In-line fuel filter
2. Breather hose 11. Fuel hose (low pressure fuel pump to fuel vapor separator) 20. Water hose (driveshaft housing to fuel cooler)
3. IAC valve air inlet hose 12. Fuel injector 21. High pressure fuel pump
4. Air intake silencer case 13. Fuel delivery pipe 22. Evaporation hose
5. IAC valve air outlet hose 14. Fuel vapar separator 23. Fuel drain hose No.1
6. IAC valve 15. Fuel hose clamp No.2 24. Fuel drain hose No.2
7. Thermostat cover 16. Fuel hose (fuel hose connector to low pressure fuel filter) 25. Fuel drain body
8. Thermostat cover seal 17. Fuel cooler 26. Water hose (fuel cooler to driveshaft housing)
9. Thermostat 18. Fuel hose (high pressure fuel pump to fuel delivery pipe)
4B-5 Fuel / Water Hose Routing:

2
1

3
4

IFL311420004-01

1. IAC valve bracket 3. IAC valve air inlet hose 5. Breather hose
2. IAC valve 4. Air intake silencer case
 Prepared by

Outboard Motor Engineering Department

May, 2014
Manual No. 99500-94L10-01E
Printed in Japan

372
 TOP

99500-94L10-01E

99500-94L10-01E
2014

DIC567 Pantone 303C Pantone 485 Pantone 294 Black

99500-94L10-01E DF25A/30A Service Manual Cover for PS printing (14mm) 5/0 2014/05/24 BOTTOM